Reinforced Polymer Composites Research Articles

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.

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

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.

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.

Nondestructive Testing and Evaluation of Glass Fiber Reinforced Polymer Composites Using Pulse Compression Favorable Analysis Approach

Nondestructive Testing and Evaluation of Glass Fiber Reinforced Polymer Composites Using Pulse Compression Favorable Analysis Approach

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.

Investigating gradient temperature control for enhanced interfacial bonding behavior in material extrusion 3D printing continuous fiber reinforced polymer composites

Interlayer delamination is a significant concern for composites manufactured by fused filament fabrication (FFF) process. To address the problem of interlayer delamination and enhance the macro-mechanical properties of FFF fiber composites, it is necessary to improve the adhesive bonding in the manufacturing process. Therefore, a novel method is provided to improve the interfacial bonding behavior of composites by controlling the nozzle temperature gradients in FFF composites along the build directions during the process. Results showed that the value of the first reheating peaks, in thermal history curves under gradient nozzle temperature settings, reached the effective temperature ranges (between melting temperatures and crystallization temperature). This enhanced the adhesive bonding between each layer. Finally, both experimental and theoretical approaches confirmed that the proposed method could enhance the interfacial behavior of FFF continuous fiber filled composites.

Influence of Milled carbon fiber MCF on mechanical and dynamic mechanical behaviour of carbon fiber fabric reinforced polymer composites

Carbon fiber reinforced polymer (CFRP) composites are widely used in engineering applications. Better understanding about the thermo mechanical properties of CFRP composites are essential for their development. Static and dynamic mechanical properties of CFRP composites can be modified by the filler materials loaded on it. This study investigates the effect of Milled Carbon Fiber (MCF) filler reinforcement on flexural and thermo-mechanical properties of CFRP composites. Fabricated composites are quasi isotropic laminates with unidirectional carbon fibers. The composite laminates were fabricated by hand lay-up technique. XRD analysis illustrates that all the processed specimens are in non-crystalline nature. Three-point bending mode is followed to evaluate the flexural and Dynamic Mechanical Analysis (DMA) tests. MCF fillers are loaded at 6 wt%, 8 wt%, 10 wt%, 12 wt% to evaluate above mentioned properties, i.e, Flexural Strength and Break strain were found from flexural analysis. Storage Modulus (E'), Loss Modulus(E’'), under varying temperature and glass transition temperature (Tg) were determined from DMA. The test results indicated that, 8 wt% of MCF filler loading improves the static and dynamic mechanical properties of CFRP composites when compared to 10 wt% and 12 wt% of MCF content.

Study of the effective fraction of areca nut husk fibre composites based on mechanical properties

Areca nut husk fibers have the potential to be used as reinforcement in polymer composites as a substitute for synthetic fibres. In the manufacture of fibre composites, one of the important factors in determining the strength is the matrix to fibre ratio. This study aims to determine the effective ratio or fraction between areca nut husk fibre and orthophthalic polyester resin. Before using areca nut husk fibre, it was chemically treated so that only cellulose remained in the fibre. The areca nut husk fibre was processed into sheets. The composite was manufactured using the hand lay-up technique. Tensile and flexural tests were carried out to determine the mechanical properties. Based on the results of the tests conducted, there are differences in the mechanical properties of the composites. The tensile test results show that the 40% fibre fraction has the highest tensile strength and modulus values. On the other hand, in the flexure tests, the highest tensile strength and modulus values are found in the 30% fibre fraction.

Statistical analysis to examine the influence of thermal aging on hybrid glass epoxy polymer composites with fillers of multi‐walled carbon nanotubes

AbstractE‐glass fibers are widely preferred due to ease of processing and its low cost, which has substantial scope in the fields of electronics and electrical insulation applications. Because of its low strength and corrosion resistance, use of E‐glass fibers is limited in aerospace and automotive applications. There is a need for enhancing the properties of the composite to overcome such limitations. Therefore, an attempt is made to introduce multi‐walled carbon nanotubes (MWCNT) as fillers into E‐glass fibers to meet the industry needs. In the current study, woven glass fiber of 5 layers and multi‐walled nano carbon fillers of 2, 4 and 6 by wt%, LY556 epoxy resin, and HY951 hardener were used to prepare 4 different type of composites along with the neat epoxy glass fiber reinforced polymer composites (GFRP). The hand‐layup route was used in the composite preparation due to its low cost, technological feasibility, and simple process setup. The developed samples were characterized for mechanical properties via tensile, flexural and impact tests. Tribological characteristics were performed by air jet erosion test. Chauvenet's criterion is applied for identifying the outliers (if any) from the data of repeated test properties. Taguchi's (orthogonal array) is selected for obtaining optimal hybrid composite, which yield better mechanical properties. Empirical relations are developed for the material properties in terms of process variables. The sample (4 wt% MWCNT) exhibited enhancement of 17.27% in tensile strength, 6% of impact strength and 7.3% of flexural strength when compared with neat epoxy GFRP. This hybrid composite is considered for thermal aging and observed at 60°C, 8% increase in tensile, 7% increase of impact and 15% in flexural strength due to the precipitation on carbon nano tubes along the gain boundaries. The present study recommends 4% MWCNT fillers in developing hybrid glass epoxy polymer composites for use in aerospace, automotive and civil construction industries due to economic and technological feasibility.Highlights Utilize low‐cost E‐glass fibers in electronics and electrical insulation applications. Improve composite properties for aerospace and automotive industries. Develop hybrid glass epoxy composites with 2 to 6 wt% MWCNT fillers. Examine wear characteristics under air jet erosion and study the impact of thermal aging on mechanical properties. Apply Chauvenet's criterion for outlier identification in measured properties datasets.

Optimized random forest model for predicting flexural properties of sustainable composites

AbstractIn an era of technological advancements, the quest for sustainable products has taken a center stage. The utilization of natural fiber reinforced polymer composites has become crucial in the manufacturing of eco‐friendly products due to their low cost, renewability, biodegradability, and comparable properties to synthetic composites. Coir‐based composites have been utilized in roofing, composite panels, furniture, and bio‐based insulation applications, providing enhanced strength and sustainability. In the current investigation, an exploratory data analysis (EDA) was conducted to understand the relationship between the various input variables and the flexural properties of short coir polymer composites (SCPCs). The data analysis revealed that manufacturing process had a significant impact on the flexural properties of SCPCs. Based on the insights gained from the EDA, an optimized Random Forest prediction model was developed to predict the flexural properties. Genetic algorithm approach for hyperparameter optimization led to lower objective loss in contrast to Bayesian optimized Random Forest model. The model's performance was subsequently evaluated through holdout validation, and the outcome demonstrated the model's proficiency in accurately predicting the properties. The developed model can be used as a tool for optimizing the design of SCPCs for specific applications, by predicting the flexural properties of the composites.Highlights Flexural behavior of short coir polymer composites was analyzed and modeled. Manufacturing process has the highest impact on the flexural properties. Random forest model predicted the flexural properties with high accuracy. Genetic algorithm optimized model further enhanced the model performance. The developed framework provides insights into designing biocomposites.

Carbon-nanotube-grafted glass-fiber-reinforced composites: Synthesis and mechanical properties

Glass fibers (GFs) are commonly used as reinforcements for advanced polymer composites. To improve the interfacial shear properties and mechanical properties of GF-reinforced composites (GFRPs), carbon nanotubes (CNTs) are directly grafted onto GFs using chemical vapor deposition (CVD). However, this process requires high temperatures, which causes thermal degradation of GFs, deteriorating their mechanical properties. In this study, a low-temperature CNT-grafting process was investigated using a bimetallic catalyst introduced onto a GF fiber surface via precursor solutions. The mechanical properties of the CNT-grafted GFs fabricated at different CVD temperatures were evaluated; they consistently showed low tensile strengths at temperatures above 400 °C. Subsequently, various CNT-grafted GFRPs were manufactured, and their mechanical properties were characterized. Interestingly, the flexural strengths of the composites increased with maintained tensile strength, despite a deterioration of the CNT-grafted GF reinforcements due to the CVD process. This could be attributed to the improved interfacial shear strength (IFSS) of the CNT-grafted GFs at the fiber level, and the enhanced compressive strength and interlaminar shear strength (ILSS) of CNT-grafted GFRPs at the composite level. Considering the properties of GF through CVD processes, particularly in relation to temperature, and factors such as IFSS, ILSS, tensile, compressive and flexural properties of composite materials, grafting CNTs on GF via a CVD system demonstrated its highest optimality at 450 °C.

Characterization of novel natural cellulose fiber from Ficus macrocarpa bark for lightweight structural composite application and its effect on chemical treatment

This study investigates Ficus Macrocarpa tree bark fibers (FMB) as a sustainable alternative reinforcement for polymer composites. The Industrial Revolution marked the evolution of polymer composites with synthetic material reinforcement, leading to environmental concerns. Natural fibers have recently gained prominence as efficient alternatives for polymer composites. Despite numerous natural fibers being considered, ensuring a sustainable raw material source remains crucial. In this study, fibers were extracted from FMB and subjected to alkali treatment to evaluate their impact on physical, chemical, and thermal properties. Initially, the extracted fibers measured 253.80 ± 15 μm in diameter, reduced to 223.27 ± 12 μm post-alkali treatment. Chemical analysis showed an increase in cellulose content to 59.7 wt%, a 23.34 % improvement over untreated fibers (48.4 wt%). The crystalline index for untreated and treated fibers measured 80.20 % and 84.75 %, respectively, with no noticeable changes in the cellulose phase. Additionally, the crystalline size increased to 3.21 nm. Thermogravimetric analysis demonstrated enhanced stability of treated fibers up to 378.87 °C, while the kinetic activation energy remained constant at 64.76 kJ/mol for both the treated and the untreated fibers. The alkali treatment further improved surface roughness to 39.26, confirmed by scanning electron microscopic images. These findings highlight the potential of cellulose fibers from Ficus Macrocarpa bark as a sustainable and environmentally friendly replacement for synthetic fibers in polymer composites. The enhanced physical properties and excellent thermal stability make them a promising choice for eco-conscious materials.

Development of hBN/natural fibres reinforced polymer composites using grey relation grade analysis for thermal and electrical applications

The objective of this work is to enhance the thermal conductivity and electrical properties of polymer hybrid composites through a systematic novel grey relation grade analysis (GRGA) optimization approach. This involves reinforcing the hybrid composites with hexagonal boron nitride (hBN) and various kinds of natural fibers or fillers. The development of a unique technology to produce multiphase composites using 2% of natural fibers or fillers such as coir fiber, rice husk filler, wood filler (WF), banana fiber (BF) and sugarcane fiber along with hBN (1, 3, 5 wt.%) particulates as reinforcements in epoxy matrix. The Taguchi L15 matrix array is utilized to fabricate interlaced composite samples via hand layup molding. Ultrasonic waves are used to ensure the uniform distribution of hBN filler into the matrix. Analysis of variance and GRGA reveal the significant results. It shows that the multiphase hybrid composites exhibit good thermal conductivity when higher content of hBN (5 wt.%) particulate for all the micro particulate polymer (MPP) composites. Multi-response optimization shows that the micro BF (2 wt.%) interlaces with hBN (5 wt.%) composite exhibits the higher thermal conductivity and electrical resistance compared to all other natural fiber interlaced composites. The aforementioned MPP composite has thermal conductivity of 1.03 W (m·K)−1 and electrical resistance of 279.88 Giga Ohms. Besides, the WF interlaced hBN (5 wt.%) composite shows the minimum dielectric constant compared to all other natural fiber composites. This desirable result is caused by the proper dispersion of hBN with the matrix which encourages interlocking with the fiber and the matrix. Maximum electrical resistance is observed for composite containing 5 wt.% of h-BN and 2 wt.% of BF. The developed MPP composite could be used in heat shields, electrical insulation components, and interior automotive components like dashboards, luggage compartments and interior walls.

Effect of alumina fillers on physical and mechanical properties of luffa/groundnut shell natural fiber reinforced polymer composites

AbstractThis study aims to investigate the physical and mechanical properties of epoxy composites reinforced with hybrid luffa waste and groundnut shell waste natural fibers and to evaluate the effect of different filler loadings of alumina on the mechanical behavior of the hybrid composites. The luffa fibers were made to undergo mercerization in 10% NaOH solution. All the treated fibers and the alumina fillers were characterized using X‐ray diffraction analysis (XRD). The study used three different filler loadings of alumina (Al2O3) (5%, 10%, and 15% by volume) and three different fractions of treated luffa‐waste groundnut shell hybrid fibers (10%, 30%, and 50% by volume). The composites were fabricated using the hand layup technique, and the prepared test specimens were subjected to mechanical and physical properties testing as per ASTM standards. The experimental findings indicated that the inclusion of Al2O3 filler improved the physical and mechanical characteristics of the natural fiber‐reinforced hybrid composites. The results showed that the composites with 30 vol. % fibers (1:1 luffa fiber: groundnut shell fiber) and 10 vol. % Al2O3 content showed enhanced tensile, flexural, shear, and impact strength and hardness. Besides, a good synergy between the alumina fillers, natural fibers, and the polymer matrix was observed in the surface morphology of the composite specimen. The developed composites can be used in low and medium‐load‐bearing structural and non‐structural applications.Highlights Development of hybrid polymer composites with luffa and novel groundnut shell fibers Hybridization of alumina ceramic particles with natural fiber hybrid composites Assessment of physical and mechanical properties of the polymer composites

Extraction and characterization of a new natural cellulosic fiber from the Habara Plant Stem (HF) as potential reinforcement for polymer composites

In this present work, characterize the chemical, physical, thermal and Morphological behaviour of raw and alkali-treated (NaOH 5 %,10 % & 15 %) new natural cellulose Habara plant stem fiber (HF). From the chemical analysis, the 10 % alkali-treated HF obtained cellulose (67.9 %), hemicellulose (12.7 %), lignin (11.8 %) wax (0.18 %), moisture (2.44 %) and Ash (1.21 %). Fourier Transform Infrared Spectroscopy Analysis, alkali treatment effectively eliminates hemicellulose and lignin from the surfaces of natural fiber, as seen changes in the FTIR peaks at 1730, 1480, and 1140 cm−1.The X-ray analysis results indicate that, there is crystalline cellulose present, with a crystallinity level of 43.87 %, and that the other components are amorphous. In addition, the thermal stability of lignocellulosic fiber up to 230 °C was observed, and the degradation steps of each major component could be identified. The 10 % alkali-treated HF provides tensile strength of 790.9 MPa, with an elongation at break of about 3.41 %. The Scanning Electron Microscope analysis showcased the morphological changes on the fiber fractured surface, diameter variation, and impurities, etc. The Atomic Force Microscopy was used to determine the surface roughness characteristics of the HF, which confirmed the possible reinforcement in the structure of the polymer matrix composite structure.

Suitability Evaluation of Raw and Alkali-Treated Cannonball Fibers as Reinforcement in Polymer Composites

Suitability Evaluation of Raw and Alkali-Treated Cannonball Fibers as Reinforcement in Polymer Composites