Matrix Composite Materials Research Articles

A numerical oxidation model for SiC‐coated thermal protection systems in hypersonic applications

AbstractSilicon carbide (SiC) is a widely used component for thermal protection system (TPS) design. This material is often used either as a coating layer to protect beneath carbon‐based material against oxidation or as a ceramic matrix for composite materials used in the hypersonic leading edges. A numerical equilibrium model for SiC‐coated material ablation is developed in this study to compute the material response of coated TPS in hypersonic relevant aerothermal environment. The developed model is based on an equilibrium approach similar to the carbon graphite oxidation framework for ablative charring materials. The equilibrium wall composition is calculated based on the minimization of the Gibbs free energy. The proposed method can capture numerically the transition from passive to active oxidation while maintaining a low computational cost and good numerical stability. Implementation of the model in the Porous Material Analysis Toolbox based on OpenFOAM code permits to compare against previous literature test cases. By comparing the surface temperature obtained from the model with the experimental data, it is observed that the numerical model gives a good estimation providing accurate surface temperature prediction.

Achieving back-stress strengthening at high temperature via heterogeneous distribution of nano TiBw in titanium alloy by electron beam powder bed fusion

Back-stress strengthening has been proven to be an effective strategy in breaking the room temperature strength–ductility dilemma in hetero-structural metals matrix composite materials (MMC). However, back-stress is difficult to achieve at high temperature because of grain boundary softening, grain boundary sliding, dislocation annihilation and grain rotation. Here, back-stress strengthening is exploited to improve the high temperature tensile properties of Ti-6Al-4 V (TC4) alloy by precipitating a heterogeneous distribution of nano TiB whiskers (TiBw). In this work, the rapid solidification associated with electron beam powder bed fusion (EB-PBF) generates heterogeneous in-situ nano TiBw at both grain boundaries and grain interiors. The nano-TiBw on the grain boundaries (GB nano-TiBw) not only refines the grains but can also pin the grain boundaries. The intragranular nano TiBw (IG nano-TiBw) significantly reduces the dislocation mean free path, inhibit dislocation movement, and dramatically enhances the dislocation storage density. Meanwhile, specimens are strengthened by high-density < a + c > dislocations induced by the precipitated nano TiBw. The heterogeneous distribution of nano TiBw achieved a 50 °C increase in the service temperature of TC4 alloy while also increasing stability. This strategy provides a new perspective for further improving the high-temperature mechanical properties of titanium alloys.

Characteristics and degradability of laser print waste paper fiber reinforced PLA resin matrix composite materials

AbstractAs is well known, Laser print paper is usually produced with high‐quality chemical wood pulp. The laser print waste paper fiber (LPWF) is a high‐quality secondary fiber, and the research and development of high‐value utilization technology for laser print waste paper has attracted much attention in the field of renewable resource recycling. In this study, LPWF was used to reinforce poly(lactic acid) (PLA) composites in the field, and the composites were modified with bioenzyme, cationic polyacrylamide (CPAM), and nano‐silicon carbide (Nano‐SiC) to enhance the interfacial compatibility of LPWF/PLA composites. The study systematically investigated the effects of various modification methods on the characteristics and degradability of composites made from laser print waste paper fiber reinforced PLA resin matrix. The results showed that the mechanical properties of the composites treated with CPAM and Nano‐SiC were significantly improved, with tensile strengths of 54.3 and 59.5 MPa, and flexural strengths of 85.1 and 91.5 MPa, respectively, and the water absorption of the composites was reduced after the modification treatment, while the thermal stability was improved. The degradation performance of the composites in various water environments indicated that the inclusion of LPWF accelerated the water degradation rate of the composites, with the maximum degradation rate of the composite reaching 1.26% in 30 days.Highlights Laser print waste paper is an excellent quality recyclable fiber resource. Four modifiers were used to modify LPWF/PLA composites. Characteristics and degradability of the composites were investigated. Significantly improved properties of CPAM and Nano‐SiC modified composites. The degradation rate of composites is increased by the addition of LPWF.

Cold Spray Technology and Its Application in the Manufacturing of Metal Matrix Composite Materials with Carbon-Based Reinforcements

Cold spray technology, as an emerging surface engineering technique, effectively prepares hard coatings by high-speed projection of powder materials onto substrates at relatively low temperatures. The principal advantage of this technology lies in its ability to rapidly deposit coatings without significantly altering the properties of the substrate or powder materials. Carbon-based materials, especially carbides and diamond, etc., are renowned for their exceptional hardness and thermal stability, which make them indispensable in industrial applications requiring materials with high wear resistance and durability at elevated temperatures. This review elucidates the fundamental principles of cold spray technology, the key components of the equipment, and the properties and applications of hard coatings. The equipment involved primarily includes spray guns, powder feeders, and gas heaters, while the properties of the coatings, such as mechanical strength, corrosion resistance, and tribological performance, are discussed in detail. Moreover, the application of this technology in preparing metal matrix composite (MMC) materials with carbon-based reinforcements, including tungsten carbide, boron carbide, titanium carbide, and diamond, are particularly emphasized, showcasing its potential to enhance the performance of tools and components. Finally, this article outlines the challenges and prospects faced by cold spray technology, highlighting the importance of material innovation and process optimization. This review provides researchers in the fields of materials science and engineering with a comprehensive perspective on the application of cold spray technology in MMC materials with carbon-based reinforcements to drive significant improvements in coating performance and broaden the scope of its industrial applications.

Electro-mechanical analysis of nanostructured polymer matrix composite materials for 3D printing using machine learning

Recently, additive manufacturing (AM) techniques like 3D printing have emerged as a potentially game-changing example of digital manufacturing. However, high entry barriers of a tiny material library, different processing defects, and unpredictable product quality are still holding back its widespread use in the industry. Due to its remarkable success in data tasks like classification, regression, and clustering, machine learning (ML) has recently gained a great deal of interest in the subject of the material library. This paper examines the current state of ML applications in several key areas of AM, including polymer matrix composite materials and machine parameter optimization. Composite filaments have been extruded using Polylactic Acid (PLA) as it is a biodegradable material and shows how High-Density Poly Ethylene (HDPE) enhances physical strength. All the parameters for the filament extruder have been designed by machine learning. Thermal stability is a significant concern for polymers that have been overcome by introducing Titanium Dioxide nanoparticles. The microstructure, surface texture, electro-mechanical behavior, and other general features of extruded filaments made from recycled plastics have been investigated. The extrusion temperature, approximated using ML, is in excellent agreement with the surface texture and microstructure of the polymers, as confirmed by FESEM, EDX, and Particle analysis. Extruded filaments experienced 2500 Vs and confirmed their non-conductivity up to 77.7GΩ. Tensile strength and elongation at break, two measures of mechanical properties, have been examined. Incorporation of Titanium Dioxide Nanoparticles improved mechanical properties significantly. When it comes to 3D printing, the physical properties and potential uses of each composite material are different.

The relationship between ceramic additives among structural, morphological, shielding, and stopping power features of BN/ZnFe metal matrix materials

Ionizing radiation has many negative effects on human health. These include eye and skin disorders and DNA damage inside cells. To eliminate or reduce these destructive effects of radiation, economical, low-corrosion, effective shielding materials with high absorption properties are needed. In this study, zinc-iron-based metal matrix composite materials with various proportions of boron nitride were produced on steel substrates. The structural and surface properties of the materials were examined with XRD and SEM images, respectively. These structures were irradiated with radioactive Am-241, Sr-90, Na-22, and Co-60 sources for their radiation shielding properties. Then, the absorption ratios in the samples were investigated according to the reinforced ceramic amounts in their content. In addition to the experiment, the stopping power and range values of the samples were calculated to check the reliability of the results. ZnFe alloys and composites are based on the dominant peaks of the heta (ƞ) phase of zinc. The amount of boron nitride added to the electrolyte significantly affected the crystal structure, while the incorporation of boron nitride into the zinc-iron matrix impressed the average grain size of the coating. The microstrain and dislocation densities of the film first decreased to 15 g/L and then increased depending on the ion diameter. The BN doping made the porous surface smooth, crack-free, and compact. It was found that the absorption rates for radiation increased as the amount of boron nitride in the samples increased. According to the rising amount of boron nitride, the absorption percentages are between 1.88 and 6.19% for alpha particles, 0.78–3.06% for electrons, 0.77–6.56% for positrons, and 0.61–6.34% for gamma photons. When the stopping power and range values were averaged, the amount of boron nitride increased directly and inversely with the stopping power and range values, respectively.

New Insights into the Application of Biocompatible (Un)Modified TiO2 and TiO2-ZrO2 Oxide Fillers in Light-Curing Materials.

A novel UV-light-curable poly(ethylene glycol) diacrylate matrix composite material with unmodified and methacryloxyl-grafted TiO2 and TiO2-ZrO2 systems was developed and tested as a potential coating material for medical components. The main goal of the research was to evaluate how the addition of (un)modified inorganic oxide fillers affects the properties of the composition (viscosity, UV/Vis spectra), the kinetics of photocuring (photo-DSC), and the morphological (SEM), physicochemical, and thermal properties (DSC, TGA) of the resulting composites. The applied filler functionalization process decreased their polarity and changed their size, BET surface area, and pore volume, which influenced the viscosity and kinetics of the photocurable system. In addition, the addition of synthesized fillers reduced the polymer's glass transition temperature and increased its thermal stability. It was also observed that additional UV irradiation of the tested composite changed its surface, resulting in hydrophobic properties (with the addition of 7 wt.% filler, an increase in the contact angle by more than 45% was observed).

Fabrication and mechanical properties of a high-performance PEEK-PEI hybrid multilayered thermoplastic matrix composite reinforced with carbon fiber

This paper presents a method for manufacturing a hybrid matrix composite material reinforced with a woven carbon fiber that combines the properties of two thermoplastic polymers: PEEK (polyether-ether-ketone) and PEI (polyether-imide). The manufacturing process involves a multilayer architecture and a single hot-pressing consolidation step. Experimental tests — including uniaxial tensile tests, delamination tests in Mode I and impact tests at low velocities — were conducted to compare the resulting laminate with single matrix materials (PEEK/CF and PEI/CF).The improvements in strain to failure by 48 % in tensile tests with fiber orientation at ±45∘ and in delamination force by 13 % in low velocity impact tests with respect to PEI/CF show that the heterogeneous matrix blend maintains the crystalline content and excellent elastoplastic response of PEEK while taking advantage of the affordability, lower processing temperature and toughness of PEI.

Research on cryogenic high-speed drilling performance of metal matrix composite materials (Al/SiC) using cryogenically treated drills

Research on cryogenic high-speed drilling performance of metal matrix composite materials (Al/SiC) using cryogenically treated drills

Polymer composite additive manufacturing: Applications, challenges and opportunities

Polymer composite prototypes and final products have been produced using additive manufacturing (AM) or three-dimensional printing (3DP). Due to their exceptional physical, chemical, mechanical, and structural properties, composite or reinforced materials, particularly polymers, are gaining popularity in the fields of engineering and science. High-performance printable polymer composites are urgently required due to the mechanical and functional limitations of printed pure polymer components. Customizable geometry, reduced waste, and accessible material shifting are among the benefits of 3D printing. The market expansion of young industrialists may be restricted by the necessity to recognize the potential of 3DP technology. Furthermore, the literature on this subject must be more specialized or cohesive in order to expand beyond the fundamentals for professionals. This article explores the application of 3D printing matrix composite materials with enhanced properties in the fields of electronics, medical, cars, and aircraft. FDM, PLP, DLP, SLA, SLS, and robocasting are among the AM processes that are addressed in this document. Additional applications for these materials are recommended. Finally, the advantages and disadvantages of 3D printing are highlighted in order to facilitate enhancements.

A Review on the Development of Processing Techniques for the Production and Casting of Al-Alloy and Metal Matrix Composite Material

A Review on the Development of Processing Techniques for the Production and Casting of Al-Alloy and Metal Matrix Composite Material

Influence of sodium on the structure and properties of aluminum matrix composite materials based on pseudobinary eutectic

Influence of sodium on the structure and properties of aluminum matrix composite materials based on pseudobinary eutectic

A Review on Traditional Processes and Laser Powder Bed Fusion of Aluminum Alloy Microstructures, Mechanical Properties, Costs, and Applications.

Due to its lightweight, high strength, good machinability, and low cost, aluminum alloy has been widely used in fields such as aerospace, automotive, electronics, and construction. Traditional manufacturing processes for aluminum alloys often suffer from low material utilization, complex procedures, and long manufacturing cycles. Therefore, more and more scholars are turning their attention to the laser powder bed fusion (LPBF) process for aluminum alloys, which has the advantages of high material utilization, good formability for complex structures, and short manufacturing cycles. However, the widespread promotion and application of LPBF aluminum alloys still face challenges. The excellent printable ability, favorable mechanical performance, and low manufacturing cost are the main factors affecting the applicability of the LPBF process for aluminum alloys. This paper reviews the research status of traditional aluminum alloy processing and LPBF aluminum alloy and makes a comparison from various aspects such as microstructures, mechanical properties, application scenarios, and manufacturing costs. At present, the LPBF manufacturing cost for aluminum alloys is 2-120 times higher than that of traditional manufacturing methods, with the discrepancy depending on the complexity of the part. Therefore, it is necessary to promote the further development and application of aluminum alloy 3D printing technology from three aspects: the development of aluminum matrix composite materials reinforced with nanoceramic particles, the development of micro-alloyed aluminum alloy powders specially designed for LPBF, and the development of new technologies and equipment to reduce the manufacturing cost of LPBF aluminum alloy.

Impact response characteristics and damage mechanism of continuous carbon-fiber-reinforced magnesium matrix composite materials

The continuous carbon-fiber-reinforced magnesium matrix composite (C_f/Mg) is a new type of composite material made of a magnesium alloy sheet and carbon-fiber-reinforced composite material with alternating layers. It has the advantages of high damage tolerance, light weight, and corrosion resistance, and has become the first choice of lightweight materials in aerospace, transportation, and other fields. Because impact-resistance serves as an important index for its structural design and performance stability, a continuous carbon-fiber-reinforced magnesium matrix composite with indirect bonding using a modified epoxy resin was designed in this study. Moreover, C_f/Mg was chosen to be the object of research through the selection of constituent materials such as magnesium alloys, carbon fibers, resins, and other properties, which matched the aim of realizing a lightweight material. With the help of hot-compression molding technology, dynamic impact mechanical behavior, and damage analysis technology, the structural design and preparation process optimization of epoxy resin carbon-fiber prepregs and magnesium alloy layer materials, as well as the dynamic impact mechanical response characteristics and damage evolution process under different impact energy conditions, were studied. Accordingly, through a combination of low-velocity impact experiments and numerical simulations, the effects of continuous multiple impacts at the same location with the same impact energy, as well as impacts with the same impact energy and different punch diameters, on the low-velocity impact damage behavior and dynamic impact response characteristics of C_f/Mg were investigated. The results of this study show that when the 5J impact is applied four times consecutively, the peak impact load gradually increases with the increasing number of impacts. Moreover, the peak impact loads of the second, third, and fourth impacts increase by 6.09%, 10.7%, and 14.5%, respectively, compared with the results of the first impact.

Reinforcing effects of ground tyre rubber on physical, mechanical, and thermal properties of polyethylene terephthalate

This study examines the use of waste and recyclable polyethylene terephthalate (rPET) along with micro-sized ground tire rubber (GTR) to produce a polymer matrix composite (PMC) material. The PMC materials are made in a Twin-screw extruder, with different ratios of rPET to GTR ranging from 90:10 to 50:50. In order to assess the performance of the newly created rPET-GTR matrix composite materials, the physical, mechanical properties are empirically observed. The thermal properties and crystallinity (Xc) of PMC materials are analysed using DSC. SEM and microscopic imaging are used to determine the characteristics of rPET-GTR composite materials, including elemental compositions like carbon, oxygen, and silicon. The functional group and chemical structure are confirmed through IR spectra analysis using FTIR techniques. The inclusion of micro-sized GTR has shown a significant effect on the physical (density = 1.306 - 1.208 g/cm3, water absorption = 1.76%–10.74%, and melt flow index = 8.12 - 12.79 gm/10 min), mechanical (tensile strength = 52.78 – 73.58 MPa, impact strength = 110.64 - 138.44 J/m, hardness = 56.14 - 76.37, and flexural modulus = 66.23 - 106.32 MPa), and thermal (melting temperature = 220.25°C–192.57°C, Xc = 20.30 to 30.58%) properties of rPET. These studies all work together to improve the performance of waste rPET and GTR materials by repurposing them. It helps to promote sustainability, cost-effectiveness, and expands the range of applications (automotive parts, building materials, sports equipment, electrical insulation and prosthetics) for rPET-based composites with potential uses in the polymer industries.

Comparative Review of Mechanical Properties of Rice Straw and RiceHusk Fiber Reinforced Polymer Composite

Rice straw and rice husk fibers (RS/RH) reinforced polymer-based composites have theability to conserve wood and petroleum resources. As natural filler, rice straw and rice husk offer asustainable material for the production of polymer-based composites. The application ofbiocomposite limits the burning of straw at the root and may further enhance the socioeconomicstatus of farmers and rural populations. This review mainly focuses on five different weightpercentage of reinforced RS and RH fiber content (5%, 10%, 15%, 20% and 25%) in polymercomposites. Nowadays, Epoxy, polyurethane, polyester, PVA, PLA and polyethylene are beingused as matrix material in polymer composites. This paper holds good with understanding themechanical properties, pretreatment methods and offer important insight into potential uses ofpolymer composites with biodegradable reinforce fiber.

Effect of SiC nanoparticles on mechanical and damping properties of epoxy/polysulfide rubber blend composite

Blend polymer matrix composite material are becoming more and more popular due to their promising mechanical properties. In this research, blend polymer mixture was make from epoxy resin (EP) blended with different weight percentages of polysulfide rubber (PSR) (0, 3, 6, 10, 15, and 20%). Then tensile, impact, bending strength and damping ratio were evaluated to get the high quality of mechanical properties for the blend matrix. Due to the requirements to enhance the mechanical properties of this blend; a various weight fraction of carbide silica (SiC) nanoparticle was used as a reinforcement in the ratios of (0, 1, 3, and 5%) by weight to the best ratio of the blended matrix. Tensile, impact, bending and damping ratio tests were also conducted to get the best mechanical properties for the blend materials. Experimental results for the blend matrix showed that adding polysulfide rubber to epoxy resin resulted in a decrease in Young’s modulus, tensile strength, and bending strength; however damping ratio and the impact strength increased. It is found that the weight fraction of 6% of PSR is the Better case, which gave the better mechanical characteristics properties for mixture. Utility of this mixture; it has intermediates between flexible properties of a mixture at the highest rate of PSR and brittle mechanical properties for EP resin. Mechanical and damping properties showed an increasing when the carbide silica (SiC) with a weight fraction of 3% added, then it decreased slightly.

Ion-irradiation effect on swelling and microstructure of BN particle dispersed liquid phase sintering SiC

The boron nitride (BN) particle dispersed silicon carbide (SiC) materials were fabricated by liquid phase sintering (LPS) with Al2O3 and Y2O3 sintering additives as the reference matrix material for SiC composites. They were irradiated to 0.1/1/3/10 dpa by 5.1 MeV Si2+ ions at 800 °C. Raman spectra indicated that the pure h-BN structure was partially destroyed following irradiation, while yttrium aluminum garnet (YAG) structure at grain boundaries formed from the sintering additives wasn’t destroyed. TEM images and diffraction patterns indicated that the mechanism of microstructure evolution of SiC after irradiation up to high fluence at 800 °C was defect clusters induced by irradiation.

Experimental and Simulation Study on Low-velocity Impact Damage of Composite Laminates under Temperature Environment

The composite material casing of aero-engine operates in different temperature environments and is inevitably impacted by external objects during use. The resin matrix composite materials are sensitive to temperature, which leads to more complex damage propagation and failure modes of materials under temperature environment. The influence of temperature environment on low-velocity impact damage of composite materials needs to be studied. In this paper, the T300/QY8911 composite laminates were subjected to low-velocity impact test and simulation study under three different temperature environments of 20°C, 120°C, and 180°C. The impact damage detection was carried out by visual inspection and ultrasonic C-scan to analyze the influence of temperature on the damage of composite laminates. Finite element simulation analysis was also conducted on the gradual expansion process of impact damage of composite laminates under different temperature environments to predict the impact damage area of laminates. The results show that the main damage forms are matrix cracking and delamination and the temperature has a significant effect on the low-velocity impact damage of composite laminates. Under the same impact energy, the length of the back crack and the cracking damage of the matrix of the laminate decreases as the temperature increases; the impact damage area and the delamination damage of the laminate increases as the temperature increases.

Studies on selective laser quenching by high repetition frequency lasers with scanning galvanometer

This study introduces a novel material processing methodology termed High Repetition Frequency Selective Laser Quenching (HRF-SLQ). This technique utilizes high-power lasers with a maximum power of 5 kW in conjunction with a scanning galvanometer, operating at elevated repetition rates up to 200 Hz, to specifically treat surfaces of high and medium carbon steels. The application of this method leads to the creation of allotropic metal matrix composite materials (A-MMCs). In general, the scanning speed of a galvanometer can range from hundreds to thousands of times per second. Based on the high acceleration and rapid jumping characteristics of the scanning galvanometer, this technology transforms the high-power laser heating of metal plates from continuous heating mode to parallel pulse heating mode, which repeats heating 30 to 200 times per second. This transformation ensures the quenched layer avoids melting even under prolonged irradiation times by high-power lasers. Consequently, it can significantly enhance processing efficiency by selective laser quenching (SLQ), ensuring that the depth of the hardened layer reaches 0.88–0.94 mm and keeping the surface smooth without melting. This paper systematically investigates the influence of various processing parameters, such as laser power (P), single heating time (t1), and the number of processing units (N), on the depth of the SLQ and the quenching efficiency. It also examines the impact of HRF-SLQ technology on the properties of A-MMCs and analyzes temperature field variations from room temperature to melting point through simulation methods combined with laser quenching experiments.