Strength Of Carbon Fibers Research Articles

Curved surface coupled structural battery composites manufactured by resin transfer molding process: Microstructure and multifunctional performance

To bridge industrial production and lab-scale research, this work demonstrates a technology to manufacture curved surface structural battery composites (CSBCs) that can simultaneously achieve electrochemical energy storage and load-bearing. The curved-surface carbon fiber structural anode and cathode are fabricated by coating the active materials on carbon fiber fabric with a vacuum-bag-assisted technique. The resin transfer molding (RTM) process is conducted to manufacture the coupled CSBCs by infusing bi-continuous phase epoxy resin electrolyte and curing at high temperatures. The microstructure of structural electrodes and CSBCs is characterized by scanning electron microscopy (SEM). Due to good interfacial compatibility between high mechanical strength carbon fiber structural electrode and high ionic conductivity solid polymer electrolyte bulk for load support, the fabricated CSBCs demonstrate a high density of 294 mWh kg−1 based on the whole mass of devices, a tensile strength of 257.4 MPa with Young's modulus of 12.9 GPa and a flexural strength of 194.1 MPa with flexural modulus of 11.1 GPa. In situ electrochemical-mechanical tests further confirm the durability of CSBCs under mechanical loads with a multifunctional efficiency of 1.07, suggesting the effectiveness of the introduced manufacturing techniques for coupled structural battery composites.

Comprehensive evaluation of interfacial interactions optimization for CF reinforced high-performance thermoplastic composites by electrochemical deposition of conjugated polymers

The mechanical properties of carbon fiber (CF) reinforced high-performance thermoplastic composites are significantly compromised due to inadequate interface bonding between CF and matrix. In this study, electrochemical polymerization techniques were employed to modify CFs with polypyrrole (PPy), poly-aniline (PANI), and poly-o-phenylenediamine (PoPd), to systematically investigate the impact of conjugated polymers on the interfacial properties of CF/copoly (phthalazinone ether sulfone ketone)s (PPESK) composites through a combination of experimental and molecular dynamics (MD) approaches. The findings revealed distinct differences among these conjugated polymers in terms of their effects on both IFSS and ILSS for CF/PPESK composites. Among all tested laminates, PoPd@CF-60s/PPESK exhibited the highest IFSS, ILSS and flexural strength values of 39.8 MPa, 75.6 MPa, and 1494 MPa, respectively, 94.1 %, 20.6 %, and 47.6 % higher than those of CF-desized/PPESK, without compromising CFs strength and thermal resistance of CF/PPESK composites. MD simulations combined with fracture morphology analysis confirmed that compatibility between conjugated polymers and matrix played a pivotal role in enhancing interface properties for CF/PPESK composites. Furthermore, the AFM outcomes demonstrated that the PoPd layer could serve as the modulus transition layer between the CF phase and the PPESK phase, which effectively enhancing the load transfer efficiency between the two phases under external forces. To summarize, this work presents a straightforward yet non-destructive approach that effectively enhances the interface strength within advanced CF reinforced high performance thermoplastic polymer composites (CFRHPTPs).

Carbon fibres: Effect of various thermo-oxidative environments on structural and performance damage, both alone and in composites

This study examines the effects of heat and fire on the physical, mechanical and electrical properties of carbon fibre and those in carbon fibre reinforced composites (CFRCs). Carbon fibres were exposed to controlled heating (thermogravimetric analysis (TGA) and a tube furnace) in inert and air (oxygenated) environments and simulated fire (cone calorimetry at 35–75 kW m−2 and jet fire (propane burner) of 116 kW m−2) atmospheres. In inert atmospheres there was a minimal effect on the properties of carbon fibres, but in an oxygenated environment, significant oxidation began at temperatures ≥550 °C, resulting in a reduction in fibre diameter, which reduced further with increasing temperature and exposure duration. Tensile strength and electrical conductivity of carbon fibre decreased with reduction in fibre diameter. CFRCs exposed to 75 kW m−2 in a cone calorimeter and direct flame in a propane burner (116 kW m−2) showed varying degrees of oxidation in CFRC plies, with surface ply fibres experiencing more oxidation and consequent reductions in fibre diameter and tensile properties compared to fibres in underlying plies, where oxidation was limited due to restricted oxygen availability. Fibres exposed to the propane burner exhibited notable damage, including pitting and internal oxidation. Despite this, the overall electrical properties of residual carbon fibres did not significantly decrease, indicating that they still pose an electrical hazard if exposed during a high heat or fire event.

Increasing softening point of isotropic spinnable asphalt by two-step preparation from ethylene tar residue modified with bio tar residue

Carbon fiber prepared from asphalt may be a critical type of low-weight chemical material of excellent mechanical performances. Here, an isotropic spinnable asphalt (EBA) was prepared from ethylene tar residue (ETR) by a two-step method of bio tar residue (BTR) through co-polymerization-air blowing, and isotropic asphalt carbon fibers were prepared from the product asphalt. The main types of molecules contained in the two feedstocks were determined by 1H NMR and LDI-TOF MS analyses. The co-polymerization behavior and thermal stability of the asphalt blends were analyzed using polarized light microscopy and thermogravimetric analyzer, respectively. Finally, the morphology and mechanical properties of carbon fibers made from EBA were evaluated by scanning electron microscope and universal testing machine. The results show that BTR contains much more oxygen-containing functional groups and unique long-chain sawtooth molecular structure; the former can promote the reactivity of the co-polymerization reaction, and the latter can limit the formation of large-plane cyclic aromatic hydrocarbon polymers due to the spatial resistance effect to greatly reduce the content of the mesophase. The softening point of the product asphalt shows a tendency of increasing and then decreasing with the increase of the proportion of BTR in the raw material mixture, and a reaction mechanism based on linear and bulky molecules is proposed to explain it by analogy with the structure of macromolecules. Consequently, the EBA made from a mixture of ETR and BTR at ideal moderate proportions has excellent performance in terms of softening point and mesophase content than ETRO made from ETR alone, and the carbon fiber made has a high tensile strength of 1.82 GPa with an elastic modulus of 38.9 GPa, which has reached the level of high tensile strength carbon fiber. Therefore, the use of inexpensive renewable energy bio-asphalt in the modification of heavy oil to obtain high softening point isotropic asphalt for preparing isotropic carbon fiber with excellent properties is achievable.

Development and mechanical properties evaluation of environmentally sustainable composite material using various reinforcements with epoxy

In this study, the mechanical properties of advanced composites fabricated by the hand lay-up process were investigated. The mechanical properties evaluated in this study included tensile strength, flexural strength, and impact strength. Tensile tests were performed to measure the resistance of the composites to pulling forces, while flexural tests assessed their resistance to bending. Impact tests, on the other hand, determine the material's ability to absorb sudden forces or shocks. Results showed that all the composite materials exhibited high tensile strength, with the Carbon fiber epoxy composite displaying the highest value due to the exceptional strength of carbon fibers. In terms of flexural strength, the Glass-Fiber Polymer Matrix composite demonstrated the highest resistance to bending, while the Kevlar-Epoxy composite exhibited the highest impact strength, owing to the unique properties of Kevlar fibers, which offer excellent energy absorption capabilities. In the hardness test, the Kevlar composite to epoxy matrix showed hardness from HRB 105 to HRB 125 an increase of 19.04 %, while fiberglass increased hardness by 14.2 % and carbon fiber by 16.3 %. The Impact test shows that the Kevlar composite to epoxy matrix showed hardness from HRB 105 to HRB 125 an increase of 19.04 %, while fiberglass increased hardness by 14.2 % and carbon fiber by 16.3 %. Kevlar reinforcing composite produced the highest flexural strength, compared to neat epoxy by 91.7 %. Carbon fibre composites were 52.5 % higher, whereas glass fibre composites were 15.6 % higher. SEM imaging results from the cross-sections show that the best bonding between the base material and the fibers was observed for Kevlar reinforced with epoxy. All mechanical test showed that Kevlar (Aramid fiber) provides excellent mechanical properties when compared to carbon fibre and glass fibre. Hence, Kevlar (aramid fiber) can be an option for preparing light weight helmets, automobiles, aeronautics, safety equipments etc.

Development of a novel characterization model for innovative bionic helical carbon fiber tows

The design of bionic helical structures significantly enhances load-bearing capacity and impact resistance, demonstrating great potential for mechanical property improvement. However, there is still a lack of precise characterization models for the helical structures of carbon fibers, which constrains their potential in engineering applications. This paper successfully fabricated helical carbon fiber tows using a carbon fiber twisting technique and introduced a novel intersecting circular cross-section model to thoroughly investigate the influence of the helical structure on the mechanical properties of carbon fiber tows. Tensile test results show that at a twist angle of 5°, the helical structure increases the tensile strength and fracture toughness of carbon fiber tows by 13.6% and 34.3%, respectively. Additionally, the introduction of complex structures such as helices significantly influences the material’s modulus, and precise modulus prediction is crucial for material optimization and practical application. Based on the newly proposed model, a modulus prediction model is developed, demonstrating higher predictive accuracy than traditional models with a prediction error of 2.8%. Finite element simulations further validate the practicality and superiority of the intersecting circular cross-section model. Compared to traditional models, the predictions of the novel model are closer to experimental data, with a prediction error below 2%, emphasizing the significant impact of microstructures on macroscopic properties and offering a new perspective for modeling complex material systems. These findings provide crucial theoretical and methodological support for the design and performance optimization of carbon fiber materials.

Enhanced strength and toughness of carbon fiber reinforced aluminum matrix composite prepared via novel indirect extrusion method

The fabrication of large-sized, high-performance CF/Al composites presents significant challenges for the aerospace industry. This study introduces a novel indirect extrusion (IE) method for the high-quality production of CF/Al composites. The study investigates the infiltration mechanism of the alloy liquid during the IE process, highlights the technique's advantages, and systematically analyzes the mechanical properties and failure mechanisms of CF/Al composites. Results show that the aluminum liquid initially fills the interlayers and subsequently penetrates the fiber bundles, effectively shortening the infiltration distance. At a casting temperature of 800°C and an infiltration pressure of 40 MPa, the composite exhibits excellent forming quality and microstructural integrity. Compared to direct extrusion (DE) CF/Al composites, IE-CF/Al composites show significant improvements in compressive strength (16.72 %), flexural strength (16.87 %), fracture toughness (43.18 %), and work of fracture (90.61 %). The interlayer alloy and increased fiber spacing in IE-CF/Al composites enhance energy absorption capacity and reduce the risk of brittle fracture. This process lays a solid foundation for the high-quality production and application of CF/Al composites.

The influence of process parameters and carbon nanotubes on composite material joints

AbstractThrough resistance welding experiments, the effects of process parameters and heating elements (HE) on the welding strength of carbon fiber reinforced polyamide 6 (CF/PA6) composites were studied. Stainless steel mesh was used as the heating element for welding CF/PA6 composites. The mechanical properties of the weld were tested using a universal testing machine, and the internal structure and fracture of the joint were analyzed by scanning electron microscopy (SEM). The optimal parameters for welding CF/PA6 composites were determined. In addition, the growth of carbon nanotubes (CNTs) on the surface of the metal mesh significantly improved the welding strength, from 14.016 to 16.31 MPa. The experimental results showed that the optimal parameters included 22A current, 0.3 MPa pressure and 35 s welding time, and the optimal specification of the metal mesh heating element was 200 mesh. The burning time of the metal mesh was 10 s, and the optimum pickling time was 30 s.Highlights The matrix of the composite material is nylon 6. Improved the experimental process for growing carbon nanotubes. Explore the influence of burning time on welding effect through detection.

A review on integration of carbon fiber and polymer matrix composites in 3D printing technology

Three-dimensional (3D) printing applications obtained by combining the lightness, high strength, and durability of carbon fiber with polymer matrix composites provide various industrial advantages. These advantages offer new design and production opportunities for automotive, aviation, space, medical devices, and many other industrial fields. This review article discusses material innovations in 3D printing technology with a focus on the integration of carbon fiber and polymer matrix composites. After examining the current state and future potential of 3D printing technology, the properties and advantages of carbon fiber and polymer matrix composites and the difficulties encountered with their integration into the 3D printing process were examined. In conclusion, this review article comprehensively discusses the current status, advantages, challenges, and future directions on the integration of carbon fiber and polymer matrix composites in 3D printing technology. This article can be an important resource for industry professionals and researchers in materials science and engineering.

Schematic construction of carbon fiber tow microstructure models and their effect on tensile strength of carbon fiber tow/epoxy composites: Quantification of carbon fiber distribution, misalignment, and interlacing

Carbon fiber reinforced polymers (CFRPs) are increasingly being used in cutting-edge technologies, thus rendering accurate material characterization essential. However, the unexpected microstructures of carbon fiber (CF) tows, such as random fiber distribution, misalignment, and interlacing, degrade the mechanical properties of CFRPs and render them unpredictable. Hence, the microstructures of CF tows and their effect on the performance of CFRPs must be investigated.Herein, we propose a framework for quantifying the microstructural parameters of three types of T700 grade CF tows and investigate their effects on the tensile strengths of CF tows and CF tow-reinforced composites. CF cross sections are analyzed via microscopy to measure the fiber distribution and misalignment with respect to the location. A two-roll mill experiment is designed to evaluate fiber interlacing by compressing the CF tow in the thickness direction. The tensile strengths of CFs, CF tows, and CF tow-reinforced composites are measured, whereas their interfacial shear strengths are obtained via a micro-droplet test.Two CF tow microstructure models are proposed: the uniform distribution model with a low degree of fiber misalignment resulted in a higher tensile strength ratio of CF tow compared to the core-shell model, as well as a higher tensile strength of CF tow/epoxy composites. Results indicate that the microstructure of the CF tow significantly affects the properties of the composite materials. Therefore, utilizing the framework proposed herein as a tow design parameter is expected to fulfill the varying requirements of important properties in composite material design based on the application field.

Improvement of interfacial properties and hygrothermal resistance of CF reinforced epoxy composites by fluorine-containing sizing agent

To enhance the interfacial bonding performance between carbon fibers (CFs) and epoxy resin, the fluorine-containing sizing agent was prepared by the unique characteristics of fluorine. The incorporation of C-F bonds endows the interfacial layer with a higher degree of homogeneity, effectively mitigating stress concentrations that arise from surface imperfections. This mitigation is attributed to the repulsive interactions among fluorine atoms. The test results showed that the interlaminar shear strength (ILSS) of carbon fiber reinforced epoxy composites (CFREs) can be increased to a maximum of 66.01 MPa, representing a notable enhancement of 15.79 % in comparison to unsized CFREs. The enhancement of interfacial bonding ability is primarily ascribed to the synergistic effects of mechanical interlocking and chemical bonding interactions at the interface between CFs and resin. Concurrently, the hygrothermal resistance of CFREs was subjected to rigorous testing. The electron cloud of fluorine atoms exerts a pronounced shielding effect on the carbon chains, thereby significantly bolstering the hygrothermal resistance of CFREs. This enhancement is critical for the CFREs ' application in environments with high humidity and temperature. Moreover, the sizing agent developed in this study boasts a streamlined production process, which is expected to be applied in the commercial large-scale production of CFs.

Development and characterization of hybrid polymer composite materials with reinforcement of glass/carbon fibers for enhanced mechanical properties: an experimental and numerical approach

Composite materials, particularly fiber-reinforced plastics (FRP), are used in aerospace and automotive industries due to their desirable properties and surpassing traditional metals in various applications. Researchers are countering the drawbacks of using a single fiber type in FRP by creating hybrid composites that combine different fibers in a single matrix. These hybrids harness the cost-effectiveness and corrosion resistance of glass fibers alongside the strength and stiffness of carbon fibers, resulting in a balanced combination of properties for various applications. Tensile tests were performed according to the ASTM D3039 standard, with a 2 mm/min strain rate. The results showed that increasing the carbon fiber percentage (6.56%, 13.79%, and 21.07%) led to significant improvements in the tensile strength of the hybrid composites (34.18%, 55.44%, and 85.40% higher than glass fiber composites). However, changing the stacking sequence did not significantly affect tensile strength, indicating its insignificance in this regard. Numerical simulations were conducted to validate the experimental results, and the errors between experimental and numerical data were below 10% for various stacking sequences. These discrepancies were attributed to factors such as fiber waviness, which resulted in heterogeneous property distribution within the composites, and the manufacturing process used for creating the hybrid composites. Scanning electron microscope analysis was also performed to study the failure modes on the fracture surface of the tensile-tested specimens.

Compressive strength and failure mechanism of high-modulus carbon fibers produced from polyacrylonitrile and mesophase pitch

Compressive strength and failure mechanism of high-modulus carbon fibers produced from polyacrylonitrile and mesophase pitch

Interfacial strength and its regulation in the carbon monofiber/epoxy binder system

The strength of polymer composite materials (CMs) is largely determined by the strength of interfacial interactions at a fiber/matrix interface. In this work the strength in a unit cell of CM carbon monofiber/cured epoxy matrix is investigated. The relevance of the work is due to direct measurements of strength at the monofiber/matrix interface, excluding defects of micro-droplet and technological errors associated with impregnation in a traditional assessment of polymer composite materials strength. Changes of surface morphology and energy characteristics of fibers in plasma chemical treatment process is shown. The study of fiber surface energy and formation of carbon monofiber/epoxy matrix interface of carbon fiber reinforced composite unit cell was carried out on the specially developed original device Drop-Sting test. Micro pull-out test was used to investigate the shear mechanical properties of interface and to determine the strength of carbon fiber reinforced composite unit cells before and after treatment in oxygen discharge plasma. It is shown that the increase in the strength of the monofiber/matrix interfacial interface after the treatment of carbon fiber in plasma occurs due to the increase in the surface energy and wettability of monofibers.

Boosting mechanical properties of carbon fibers by gas-liquid dual-effect approach

The tensile strength and tensile modulus of existing carbon fibers (CFs) are 3 %–5 % of the theoretical values, which greatly limits the performance of CFs when used alone or as a reinforcing material. To increase the chemical reaction activity and roughness of the surface of CFs based on the enhancement of their mechanical properties, a comprehensive treatment of CFs was carried out by the gas-liquid dual-effect method. CFs were oxidized at high temperatures after immersion treatment using cobalt nitrate solution, and the effects of cobalt nitrate solution concentration, oxidation time, and calcination temperature on the surface morphology, functional groups, structural defects, and mechanical properties of CFs were investigated by the controlled-variable method. The results showed that when the concentration of cobalt nitrate solution was 0.2 molL-1, the calcination temperature was 200 °C, and the oxidation time was 4 h, the modification effect was the best. At this time, the tensile strength of CF is 6104.50 MPa, which is 40.35 % higher than that of the pure CF, and the tensile modulus is 378.56 GPa, which is 13.27 % higher than that of the pure CF, with a significant enhancement effect. It can offer feasible ideas for further research and development of CF composites, and provide an effective way to promote the industrialization of modified CFs for application.

Effect of laser heating on mechanical strength of carbon fiber–reinforced nylon in fused filament fabrication

Effect of laser heating on mechanical strength of carbon fiber–reinforced nylon in fused filament fabrication

Outstanding interlaminar strength of carbon fiber reinforced epoxy resin via graphene oxide chemical bridge bonding

Carbon fiber reinforced polymers (CFRPs) are susceptible to interlaminar failure under high shear stress, which reduces their service life. Herein, we report a strategy to address the interlaminar damage problem of CFRPs by utilizing graphene oxide (GO) as a bridge to chemically bond carbon fibers and epoxy resin. Amino groups were grafted on the surface of carbon fibers to react with GO, then active amino functional groups were introduced onto GO, enabling crosslink with the epoxy resin. The chemical bonding force and mechanical interlocking effect of GO tightly integrated the carbon fibers with the epoxy resin, greatly reducing relative slip under high shear stress. This flexible and robust connection resulted in a significant improvement in the interfacial adhesion strength of CFRPs. The GO content and type of amino reactants were optimized to fabricate CFRPs, and the interlaminar shear strength and transverse fiber bundle tensile strength were increased to 76.36 MPa and 34.2 MPa, which were 46.2 % and 77.2 % higher than those of pre-modification materials, respectively. This research demonstrates that the chemical bonding provided by grafting graphene oxide significantly enhances interlaminar bond strength, thereby extending the service life of CFRPs and offering a promising path for manufacturing high-strength composites.

Self‐emulsifying anionic polyester sizing agents for enhancing the interfacial and mechanical properties of carbon fiber/vinyl ester resin composites

AbstractWith the increasing emphasis on environmental protection, there is a growing focus on the synthesis of water‐solvent self‐emulsifying sizing agents. In this study, five types of anionic polyester sizing agents with varying molecular weights were synthesized to explore the effect of molecular weight on the interfacial bonding strength of carbon fiber (CF) reinforced vinyl resin composites. The results demonstrated that the molecular weights of the synthesized sizing agents were precise; the particles in the sizing agents were nanometer‐sized, monodisperse, and exhibited high thermal stability. When the molecular weight was 8000, it exhibited optimal wettability for CF, leading to a substantial improvement in the interlaminar shear strength, reaching 71.8 MPa, which represents a significant increase of 22.7% compared with commercial CFs (CFF). Additionally, the interfacial shear strength was maximized at 13.23 MPa, which was significantly increased by 14.2% compared with CCF. These significant improvements in surface properties and mechanical performance were attributed to the excellent wettability of the CF surface, effective spreading performance of the sizing agent, the presence of double bonds in the sizing agent facilitating reactions with free radicals on the CF surface, and the residual double bonds further undergoing curing with the vinyl resin, promoting the reinforcement of interface bonding.

Grafting Carbon Fibers with Graphene via a One-Pot Aryl Diazonium Reaction to Refine the Interface Performance of T1100-Grade CF/BMI Composites.

In this study, a one-pot aryl diazonium reaction was used as a simple and mild method to graft graphene onto the smooth and inert surface of T1100-grade carbon fiber (CF) through covalent bonding without any damage on CF, to refine the interface performance of CF/bismaleimide (BMI) composites. XPS, SEM, AFM, and dynamic contact angle testing (DCAT) were used to characterize chemical activity, morphologies, and wettability on untreated and grafted CF surfaces. Meanwhile, the impact of the graft method on the tensile strength of CF was also examined using the monofilament tensile test. IFSS between CF grafted with graphene and BMI resin achieved 104.2 MPa after modification, increasing from 85.5 MPa by 21.8%, while the tensile strength did not decrease compared to the pristine CF. The mechanism of this interface enhancement might be better chemical bonding and mechanical interlock between CF grafted with graphene and BMI resin, which is generated from the high surface chemical activity and rough structure of graphene. This study may propose a simple and mild method to functionalize the CF surface and enhance the interface performance of composites without compromising the tensile properties of T1100-grade CF.

Enhanced graphitization and reduced radial heterogeneity of carbon fibers inheriting from irradiated/thermo-chemically stabilized PAN-fibers

The cross-section of carbon fibers (CFs) possessed radial heterostructure, which restricted its mechanical properties. In this paper, heating and γ-irradiation were integrated during PAN fibers stabilization process to improve the radial structure of CFs. The synergy between irradiation and heating during stabilization caused the decrease of ID/IG, increase of crystal size, and reduction of pore fractal dimension in whole CFs. Through Raman spectra along fibers cross-section, a radial heterogeneity was found during the whole carbonization process. The combination of γ-irradiation and heating reduced the ID/IG of core part more significantly compared to the skin part of CFs, which weakened radial heterogeneity of CFs. At the same time, it significantly enhanced the tensile strength of CFs. Subsequently, a hierarchy model with three zones containing outer-surface, sub-surface and core parts was presented to explain the evolution of tensile strength for CFs. The γ-irradiation during stabilization enhanced the structure of each part in CFs by generating more cross-linked structures.