Reinforced Polymer Composites Research Articles

Real-Time Phased Array Ultrasonic Monitoring of Debonding Growth Under Cycling Loading in CFRP

Carbon Fibre Reinforced Polymer (CFRP) composites are widely employed in diverse industries due to their specific stiffness and strength, and corrosion resistance. However, over time, service-induced damage can initiate a failure that can threaten the operation’s safety and reliability, especially in critical industries like aerospace applications. The challenge lies in identifying and monitoring the defects before they escalate into serious issues. Non-Destructive Testing (NDT) methods play a pivotal role in this scenario, aiming to detect and evaluate defects without causing harm to the material. Detecting flaws in composite materials such as CFRP remains a complex task. Traditional NDT methods often struggle to effectively pinpoint and assess defects within these intricate structures. However, recent advancements in ultrasonic testing, especially Phased Array Ultrasonic Testing (PAUT), show promise in examining the internal composition of CFRP composites with higher accuracy and reliability. This study aims to demonstrate the applicability of PAUT for real-time monitoring of debond growth under dynamic loading. The loading was applied to the test specimens up to one million cycles, and 64 elements 2 MHz linear phased array probe was attached to the specimen. The acquired signals were analyzed and could also be recorded for offline processing or archiving. To validate the credibility of the findings, the performance of PAUT was compared to Acoustic Emission (AE), a well-established method for detecting and analysing high-frequency signals emitted by materials undergoing deformation or damage. Encouragingly, both methods exhibited similar trends in capturing the growth of debond. Furthermore, to verify the final defect lengths, post-test ultrasonic C-Scans utilizing the through transmission technique were conducted, complemented by visual inspections. These assessments served to confirm the accuracy and reliability of the results obtained through Phased Array Ultrasonic Testing. Real-time monitoring of composite structures using phased array technology comprises a valuable tool for real- time assessment of debonding in the composite. As industries continue to rely on Carbon Fibre Reinforced Polymer composites for multifaceted applications, the utilization of advanced Non-Destructive Testing methodologies like Phased Array Ultrasonic Testing emerges as a cornerstone in guaranteeing their continued integrity and performance.

A Review on Failure Analysis of Date Palm Fiber Reinforced Polymer Composites

A Review on Failure Analysis of Date Palm Fiber Reinforced Polymer Composites

Investigation and selection of optimistic material for two wheeler brake disc: An experimental and finite element approach

The brake disc is a vital component in the braking system of the automobile which helps in reducing the speed or stopping the vehicle whenever required. Whereas, increasing the effectiveness of the braking system is highly challenging for the researchers to ensure safe driving by minimizing the stopping distance of the vehicle during braking. However, the performance of the braking system mainly relies on the brake disc material utilized in the braking system. In the current trend, the usage of alternate materials with a high strength-to-weight ratio is in practice to reduce the fuel consumption of the automobile. Hence, researchers concentrate on Fiber Reinforced Polymer Composites and Metal Matrix Composites to manufacture automotive components. In this research work, the performance of the existing mild steel brake rotor is correlated with brake discs fabricated using different materials such as zirconium-coated steel, AA7075+nSiCp, AA6061+nano Rice Husk Ash particles, Glass Fiber Reinforced Polymer composite, and Carbon Fiber Reinforced Polymer composites. The effectiveness of a two-wheeler braking system is reported concerning the stopping distance, disc weight, friction coefficient, and wear resistance properties of the brake disc material. Moreover, a 3D Finite Element Model (3D FEM) is also developed and the braking mechanism is simulated. The experimental and FEA results reveal that SiC reinforced AA7075 composite shows compromising properties as required such as maximum stress of 558 MPa, excellent wear resistance, good friction coefficient of 0.40, good temperature dissipation property, and effective stopping distance of 81 m.

Evaluation of Acoustic and Structural Behavior of Banana Fiber Reinforced Polymer Composites

Evaluation of Acoustic and Structural Behavior of Banana Fiber Reinforced Polymer Composites

Investigation of Carbon Fiber Reinforced Polymer Concrete Reinforcement Ageing Using Microwave Infrared Thermography Method

This study presents the utilization of the microwave infrared thermography (MIRT) technique to identify and analyze the defects in the carbon-fiber-reinforced polymer (CFRP) composite reinforcement of concrete specimens. At first, a set of numerical models was created, comprising the broadband pyramidal horn antenna and the analyzed specimen. The utilization of the system operating at a power of 1000 W in a continuous mode, operating at frequency of 2.45 GHz, was analyzed. The specimen under examination comprised a compact concrete slab that was covered with an adhesive layer and, thereafter, topped with a layer of CFRP. An air gap represented a defect at the interface between the concrete and the CFRP within the adhesive layer. In the modeling stage, the study investigated three separate scenarios—a sample with no defects, a sample with a defect located at the center, and a sample with a numerous additional random defects located at the rim of the CFRP matte—to analyze the effect of the natural reinforcement degradation in this area. The next phase of the study involved conducting experiments to confirm the results obtained from numerical modeling. In the experiments, the concrete sample aged for 10 years with the defect in the center and naturally developed defects at the CFRP rim was used. The study employed numerical modeling to explore the phenomenon of microwave heating in complex structures. The aim was to assess the chosen antenna design and identify the most effective experimental setup. These conclusions were subsequently confirmed through experimentation. The observations made during the heating process were particularly remarkable since they deviated from earlier studies that solely conducted measurements of the sample post-heating phase. The findings demonstrate that MIRT has the capacity to be employed as a technique for detecting flaws in concrete structures reinforced with CFRP.

Extraction and characterization of novel fibers from Tecoma stans Linn bark for use as reinforcement in polymer composites.

Embarking on a pioneering investigation, this study unravels the extraordinary qualities of Tecoma stans Fibers (TSFs), freshly harvested from the rachis, establishing them as prospective reinforcements for biocomposites. Delving into their intricate characteristics, TSFs exhibit a unique fusion of physical resilience, with a density of 1.81 ± 0.39 g/cc and a diameter of 234.12 ± 7.63 μm. Complementing their physical prowess, their chemical composition boasts a harmonious blend of cellulose (70.1 ± 9.06 wt%), hemicellulose (13.56 ± 4.29 wt%), lignin (7.62 ± 2.39 wt%), moisture (4.21 ± 1.56 wt%), wax (2.37 ± 0.63 wt%), and ash (1.25 ± 0.36 wt%). In the realm of mechanical strength, TSFs showcase an impressive tensile strength of 639 ± 18.47 MPa, coupled with a robust strain at failure of 1.75 ± 0.13 % and a Young Modulus of 36.51 ± 1.96 GPa. Unveiling their crystalline intricacies, these fibers reveal a microfibril angle of 14.66 ± 0.15°, a crystalline index (CI) of 63.83 %, and a crystallite size (CS) of 9.27 nm. Beyond their mechanical marvels, TSFs exhibit unwavering thermal stability, enduring temperatures up to 297.36 °C, with a Tmax reaching an impressive 392.09 °C.

Driving towards sustainability: A review of natural fiber reinforced polymer composites for eco-friendly automotive light-weighting

The automotive industry stands at a critical juncture, compelled by the imperative of sustainability to seek innovative materials for eco-friendly light-weighting. Natural fiber reinforced polymer composites (NFRPCs) have gained popularity due to their environmentally friendly nature and excellent engineering capabilities. This review paper comprehensively examines the landscape of NFRPCs in the context of automotive applications. Beginning with an overview of the ecological urgency and regulatory framework driving sustainable automotive materials, the review navigates through key advancements in NFRPC technology. The paper delineates the diverse array of natural fibers employed as reinforcements, elucidating their intrinsic properties, sources, and processing considerations. Concurrently, an in-depth analysis of various polymer matrices showcases their compatibility with different fiber types, emphasizing the critical interplay between fiber and matrix for optimal composite performance. A pivotal facet of this review manuscript lies in the rigorous evaluation of NFRPC performance across an array of metrics, including mechanical, thermal, and environmental considerations. Studies examining the interfacial interactions between natural fibers and polymers, as well as enhancements through additives and treatments, are critically assessed. Environmental and economic considerations are paramount in the quest for sustainable automotive materials. While economic evaluations delve into the viability and cost-effectiveness of widespread adoption, life cycle assessments and environmental impact analyses are evaluated to estimate the ecological footprint of NFRPCs. The paper also surveys current trends and prospects, offering insights into forthcoming innovations and directions for research. Therefore, this review article consolidates a comprehensive body of knowledge on NFRPCs for eco-friendly automotive light-weighting. By synthesizing findings from diverse studies, it provides a holistic perspective on the potential, challenges, and future trajectory of NFRPCs in the automotive sector.

Optimization Mechanism of Mechanical Properties of Basalt Fiber-Epoxy Resin Composites by Interfacially Enriched Distribution of Nano-Starch Crystals

Fibre reinforced polymer composites have become a new generation of structural materials due to their unique advantages such as high specific strength, designability, good dimensional stability and ease of large-area monolithic forming. However, the problem of interfacial bonding between the resin matrix and the fibres limits the direct use of reinforcing fibres and has become a central difficulty in the development of basalt fibre-epoxy composites. This paper proposes a solution for enhancing the strength of the fibre-resin interface using maize starch nanocrystals, which are highly yield and eco-friendly. Firstly, in this paper, corn starch nanocrystals (SNC) were prepared by hydrolysis, and were deposited on the surface of basalt fibers by electrostatic adsorption. After that, in order to maximize the modification effect of nano-starch crystals on the interface, the basalt fiber-epoxy resin composite samples were prepared by mixing in a pressureless molding method. The test results shown that the addition of basalt fibers alone led to a reduction in the strength of the sample. Deposition of 0.1 wt% SNC on the surface of basalt fibers can make the strength consistent with pure epoxy resin. When the adsorption amount of SNC reached 0.5 wt%, the tensile strength of the samples was 23.7% higher than that of pure epoxy resin. This is due to the formation of ether bond homopolymers between the SNC at the fibre-epoxy interface and the epoxy resin, which distorts the originally smooth interface, leading to increased stress concentration and the development of cracks. This enhances the binding of basalt fibers. The conclusions of this paper can provide an effective, simple, low-cost and non-polluting method of interfacial enhancement modification.

Study on Mechanical Properties of Polymer Composites Filled with Nano Egg-shell Powder

Polymeric materials, when reinforced with synthetic fibers like glass, carbon, and aramid, offer notable advantages including increased stiffness and strength-to-weight ratio compared to conventional materials such as wood, concrete, and steel. Among these options, glass fiber stands out due to its affordability and widespread availability. Glass fiber reinforced polymer composites exhibit moderate mechanical properties, which can be significantly enhanced by incorporating nano fillers like eggshell powder. This study explores the utilization of nano eggshell powder as well as methods for effectively integrating nano fillers into polymer composites to create value-added products. Four types of composites, varying in weight proportions of nano eggshell powders, were prepared using the hand lay-up technique for mechanical and thermal characterizations. Various mechanical properties including tensile strength, flexural strength, impact behavior, as well as thermal properties via TGA and DMA analysis were investigated. The results indicate that incorporating the optimal amount of nano fillers significantly improves the overall strength of glass fiber reinforced composite materials, leading to cost savings of over 30%. This suggests that nano eggshell fillers hold great potential in composite manufacturing, particularly for substituting high-cost glass fibers in low load-bearing applications.

Optimization, Sodium Hydroxide and Plantain Fibres: Mechanical Properties of Unsaturated Polyester Composites for Transtibial Prosthetic Socket

Low mechanical behaviors of natural fibres in the reinforcement of polymer composites have remain an issue of concern. This study is aimed at investigating the effect of NaOH treatment on the mechanical properties of plantain fiber for the transtibial prosthetic sockets made of polyester resin. Plantain fiber was extracted from the plantain bast using water retting techniques. The fibres were modified using alkaline treatment method of 5 – 25% for variable time of 30 to 150 minutes. It was optimized using 3-level Factorial design (3-LCD) of response surface methodology based on tensile properties of treated fibres. The polyester composites of plantain and glass fibers were prepared using hand-layup techniques. Instron Universal testing machine-3369 model was used to determine the tensile and impact properties of fibers and polyester composites. Rockwell hardness tester-RBHT/S-39 model was used to determine the hardness property. The optimum process conditions of 5 % NaOH for 119 minutes improved plantain fiber tensile strength, modulus, strain, energy, and extension by improved by 102.03, 208.07, 9.70, 210.52 and 205.73 %, respectively. The ultimate tensile strength and modulus was obtained at 10 and 12.5% fiber loading. The hardness and impact strength of NaOH modified unsaturated polyester composites was marginally more than 3.51 and 10.69% of glass fiber reinforced unsaturated composites, respectively, at 12.5% fiber loading. FTIR analysis revealed the improvement in mechanical properties. Thus, NaOH modified plantain fiber unsaturated polyester composites serves as a better alternative for making transtibial prosthetic socket.

A review on retrofitting concrete members with near‐surface mounted‐fiber reinforced polymer composites

AbstractIn an era flooded with a multitude of studies investigating the performance of concrete structures retrofitted using fiber‐reinforced polymer (FRP) materials, this review addresses the critical need for a comprehensive overview of the retrofitting of concrete members using near‐surface mounted (NSM)‐FRP composites, aiming to save time and effort while providing engineers and research community with valuable resources relevant to the field. This review focuses on the key factors influencing both the flexural and shear retrofitting processes of reinforced concrete (RC) beams, such as the percentage, type, size and geometry of NSM‐FRP reinforcement, as well as groove design, groove‐filling materials and beam depth. Moreover, the paper explores the failure modes associated with each retrofitting type, for example, debonding failures, shear/flexural failure and rupture of steel or NSM‐FRP reinforcement, to name a few. The review also delves into the bond behavior of NSM‐FRP‐bonded joints, examining factors, such as the bonded length, surface texture of NSM‐FRP reinforcement and type of bonding agent, which would affect the bond behavior and strength of the joints. The failure mechanisms associated with the bonded joints, such as interfacial bond failure, FRP rupture and splitting of the adhesive cover, are also highlighted. Finally, this compilation aims to guide engineers and researchers by offering a critical and comprehensive database for optimal designs, further development and suggesting future research directions.

Investigation of Fiber Orientation of Fused Filament Fabricated CFRP Composites via an External Magnetic Field

Abstract For carbon fiber-reinforced plastic (CFRP) composites, controlling the interior fiber distribution and orientation during the manufacturing process is a common approach to optize the structural performance of fabricated parts. However, few studies have been conducted to investigate fiber alignment during the additive manufacturing of CFRP composites. This study proposes a magnetic field controlled (MFC) method to control the fiber orientation during the fused filament fabrication (FFF) of nickel-coated carbon fiber (NCF) reinforced polymer composites. Firstly, a theoretical analysis model is established to explore the suitable magnetic field intensity for fiber rotation. Secondly, a customized FFF system with MFC components is implemented, and a polylactic acid matrix composite containing 10 wt% NCF is printed to validate the feasibility of the proposed approach. The microstructure of the printed samples is examined to assess the effectiveness of the method. Finally, uniaxial tensile tests are performed to investigate the impact of fiber orientation adjustment on mechanical properties. The experimental results reveal that the MFC method can effectively align the interior fiber orientation of CFRP composites, leading to a significant increase in the tensile strength (approximately 8.8%) and Young's modulus (around 10.5%) of the printed samples.

Improving the fracture toughness, electrical conductivity and electro‐thermal performance of hybrid glass/carbon fiber reinforced epoxy composites with surface‐sulfonated polypropylene fabrics

AbstractHybrid glass/carbon fiber (GCF) reinforced polymer composites are one of advanced composites with reduced cost, desired mechanical properties and special electrification performance. In the work, surface‐modified polypropylene (PP) non‐woven fabric was used as the interleaf for toughening these composites. The effects of the surface‐sulfonated PP fabric (PP/S) interleaves on various mechanical properties of the GCF reinforced epoxy (GCF/EP) composites were investigated firstly, including the mode II interlaminar fracture toughness and flexural strength. Comparing to the blank control sample, the GIIC of the hybrid composites interleaved with the sulfonated PP fabric was increased evidently, as well as its flexural strength. These demonstrate the great interleaving effect of PP/S fabric on the GCF/EP laminated composites. Moreover, the heterogeneous electrically conductive behavior and electro‐thermal effect of GCF/EP interleaved with and without PP/S were studied. Interestingly, comparing to the control sample, the conductivity of the interleaved GCF/EP composites increased in both two in‐plane direction. Due to the hybrid character of the plain woven GCF fabric, both the temperature increase rate and the equilibrium temperature of the GCF/EP composites were much larger than that of pure carbon fabric reinforced composites under the same electrification condition.Highlights Polypropylene fabric grafted with sulfonate group (PP/S) was fabricated. The tensile property of fabric almost unchanged after the sulfonation reaction. PP/S was more effective in toughening glass/carbon fiber/epoxy composite (GCF). PP/S increased the conductivity in in‐plane directions of the hybrid composites. GCF/EP displayed superior electro heating effect to CF/EP.

Enhanced Tribological Properties of Nano-TiO2 Reinforced Polymer Composites Fabricated via Stereolithography

Enhanced Tribological Properties of Nano-TiO2 Reinforced Polymer Composites Fabricated via Stereolithography

A shape-performance synergistic strategy for design and additive manufacturing of continuous fiber reinforced transfemoral prosthetic socket

A shape-performance synergistic design and additive manufacturing strategy was developed for the transfemoral prosthetic sockets (TPS) to fulfill the demands of customized geometry and long-term load bearing. The 3D printing path of the continuous fiber reinforced polymer composites (CFRPC) was generated by reversing the milling path of subtractive manufacturing. The mechanical properties of the 3D printed CFRPC samples were investigated as a foundation, and the customized fiber trajectories were designed based on the analyzed stress pattern of the TPS in daily gait. The CFRPC TPS with weight of 28 % less than those made by pure resin had a safety factor larger than 3 and passed the fatigue testing of 3 million cycles. The design and additive manufacturing strategy developed in this study was also applicable for other parts with freeform surfaces.

High stiffness 3D-printed continuous pitch carbon fiber reinforced polymer composites

This study presents a method for 3D printing very high stiffness pitch-based carbon fiber (CF) reinforced polylactic acid (PLA) composites using a modified open-source 3D printer. The fused filament fabrication (FFF) technique was used to fabricate the samples with alternating layers of PLA and PLA-coated pitch CF. The tensile Young’s modulus of the 3D-printed composite samples was measured to characterize the effect of different grades and volume fractions of pitch CF on the behaviour of the printed composites. Three grades of pitch CF which have different Young’s modulus were used with volume fractions ranging from 2.4 to 8.4%. Tensile tests showed that the K1392U CF reinforced composite with a 7.3% volume fraction demonstrated the highest improvement in Young’s modulus of 850% compared to neat 3D-printed PLA. This improvement is notably higher than any previous 3D-printed carbon-based composites at a relatively low volume fraction of CF. Statistical analysis showed increased Young’s modulus in all of 3D-printed composite samples tested. The experimental values were compared to the Halpin-Tsai model and suggest that some degree of fibre breakage occurred during the 3D printing process owing to the relative stiffness of the pitch-based fibers. Future directions and suggestions for process improvements are discussed.

Biotribological properties of 3D printed high-oriented short carbon fiber reinforced polymer composites for artificial joints

Short carbon fiber (SCF) reinforced polymer composites are expected to possess outstanding biotribological and mechanical properties in certain direction, while the non-oriented SCF weakens its reinforcing effect in the matrix. In this work, high-oriented SCF was achieved during nozzle extrusion, and then SCF reinforced polyether-ether-ketone (PEEK) composites were fabricated by fused deposition modeling (FDM). The concrete orientation process of SCF was theoretically simulated, and significant shear stress difference was generated at both ends of SCF. As a result, the SCF was distributed in the matrix in a hierarchical structure, containing surface layer I, II and core layer. Moreover, the SCF was oriented highly along the printing direction and demonstrated a more competitive orientation distribution compared to other studies. The SCF/PEEK composites showed a considerable improvement in wear resistance by 44 % due to self-lubricating and load-bearing capability of SCF. Besides, it demonstrated enhancements in Brinell hardness, compressive and impact strength by 48.52 %, 16.42 % and 53.64 %, respectively. In addition, SCF/PEEK composites also showed good cytocompatibility. The findings gained herein are useful for developing the high-oriented SCF reinforced polymer composites with superior biotribological and mechanical properties for artificial joints.

Tensile strength of particle reinforced composite with interfacial debonding

Strength prediction of a particle reinforced polymer composite (PRPC) is still challenging. Although a PRPC is overall isotropic, it is more difficult to predict its tensile strength accurately than a continuous fiber reinforced composite (CFRC). One reason for this difficulty is that the calculation of stress fields of the constituents in a PRPC are complicated. The other reason is that the strength of a PRPC is significantly affected by interfacial strength, which is hard to be measured directly. In our research, the discount of the composite strength after debonding is attributed to the intensifying stress concentration. Two stress concentration factors (SCFs) are derived respectively to characterize the stress fluctuations in the matrix caused by the embedded particle before and after debonding. Based on the micromechanics Bridging Model and the matrix true stress theory, these two SCFs can be applied to evaluate the interface strength and the ultimate tensile strength of the composite from the properties of its component materials. Illustrations are presented to verify the efficiency of our theory and analyze the main influencing factors on the strength of the PRPC, including mechanical properties of component materials, particle size and volume fraction

Investigation of melt flow index and tensile properties of dual metal reinforced polymer composites for 3D printing using machine learning approach: Biomedical and engineering applications

This study investigates the enhancement of mechanical properties of metal/polymer composites produced through fused deposition modeling and the prediction of the ultimate tensile strength (UTS) by machine learning using a Classification and Regression Tree (CART). The composites, comprising 80% acrylonitrile butadiene styrene matrix and 10% each of aluminum (Al) and copper (Cu) fillers, were subjected to a comprehensive exploration of printing parameters, including printing temperature, infill pattern, and infill density using the Taguchi method. The CART unveiled a hierarchical tree structure with four terminal nodes, each representing distinct subgroups of materials characterized by similar UTS properties. The predictors’ importance was assessed, highlighting their role in determining material strength. The model exhibited a high predictive power with an R-squared value of 0.9154 on the training data and 0.8922 on the test data, demonstrating its efficacy in capturing variability. The optimal combination of parameters for maximizing UTS was a zigzag infill pattern, a printing temperature of 245 °C, and an infill density of 10%, which is associated with the highest UTS of 680 N. The model’s reliability was confirmed through a paired t-test and test and confidence interval for two variances, revealing no significant difference between the observed and predicted UTS values. This research contributes to advancing additive manufacturing processes by leveraging CART analysis to optimize printing parameters and predict material strength. The identified optimal conditions and subgroup characteristics pave the way for developing robust and predictable metal/polymer composites, offering valuable insights for material design in the era of advanced manufacturing technologies.

Does hygrothermal degradation of Mode I fatigue delamination resistance in carbon fibre reinforced polymer laminates depend on the ageing conditions?

Hygrothermal ageing has detrimental effect of the fatigue delamination growth (FDG) in carbon fibre reinforced polymer laminates, and may increase the crack growth rate by a factor of ∼5. The paper examines, how this degradation for Mode I fatigue delamination is affected by the severity of the ageing conditions. Fatigue delamination tests for R = 0.1 and R = 0.5 are conducted after ageing (1) at 70 °C 85 % relative humidity (RH) and (2) immersion in 70 °C water bath (WB). Paris-type FDG characterisation is derived, in the form, which accounts for the effect of fibre bridging. It is demonstrated that parameters of FDG degradation do not differ for these two types of hygrothermal ageing. The physical reasons for this are examined using dynamic mechanical thermal analysis (DMTA) and fractographic analysis, which revealed similar irreversible degradation of the material near the fibre/matrix interface and in the matrix itself, and the similar damage mechanisms in fatigue delamination. Furthermore, this study can highlight the importance of obeying similitude principles in FDG characterisation, and provide extra information for the ISO standard development for mode I fatigue delamination in unidirectional carbon fibre reinforced polymer composites.