Unidirectional CFRP Research Articles

Numerical investigation of bond-slip behaviour between CFRP strips and concrete in shear tests under static and blast loads

The paper is structured into two main sections. In the first part, the focus is on the finite element (FE) analysis of bond slip in a single bond shear test between concrete and carbon fiber reinforced polymer (CFRP) strips under static loads. To model the test set-up, a plastic damage material model and an elastic material model are used for the concrete prism and the unidirectional CFRP strip respectively. Three approaches, including a perfect bond model, a cohesive bond model, and contact algorithms based on recent bond slip models, are employed to simulate the bond interface. The numerical model's validity is confirmed through comparison with experimental results from the literature. The paper predicts the debonding failure mode, the strain evolution along the bond length, and the delamination loads of the CFRP strip. The cohesive bond model exhibits good agreement between numerical and experimental data. In the second part of the paper, the developed FE model is tested under blast loading and compared to the experimental results of the blast tests conducted by the authors. The experimental and numerical findings highlight a significant dynamic enhancement effect on bond-slip properties due to the propagation of the blast wave within the concrete and the high loading rate.

Numerical Investigation on Strengthening of Steel Beams for Corrosion Damage or Web Openings Using Carbon Fiber Reinforced Polymer Sheets

Fiber-reinforced polymers (FRPs) have been widely used to strengthen steel structures, which could suffer from corrosion or the introduction of web openings, for utilities such as ductwork, plumbing, electrical conduits, and HVAC systems. The present numerical study involves the application of unidirectional carbon FRP (CFRP) sheets to steel I-beams, damaged due to corrosion or web openings, to regain their lost load-carrying capacity. Finite element analysis (FEA) was utilized to develop and validate three beam models against existing experimentally tested specimens. Subsequently, a parametric study was conducted investigating the effect of various corrosion levels and the number of circular web openings on the yield and ultimate load capacities of the beams. The optimum number of CFRP layers needed to strengthen corroded beams was determined and six CFRP strengthening scenarios were adopted to determine the best configurations to retrofit steel beams with openings (SBWOs). The results revealed that corrosion, introduced by thinning the bottom flange, reduced both yield and ultimate load capacities, with a nearly perfect linear reduction in ultimate load for each 2.5% thickness loss. The optimum number of CFRP layers depended on the level of corrosion damage. Furthermore, while maintaining a constant total opening area, beams with a greater number of smaller circular web openings demonstrated higher yield and ultimate load capacities than those with fewer larger openings. Out of the six adopted CFRP strengthening scenarios, three configurations that involved applying CFRP sheets to both flanges and the web effectively restored the strength of SBWOs, when adequate CFRP layers were used.

A Multi-Scale Analysis of Unidirectional Carbon Fiber-Reinforced Polymer Composite

In this paper, a multi-scale computational analysis is conducted based on representative volume element (RVE) modeling and molecular dynamics (MD) simulation of a carbon fiber-reinforced polymer composite micropillar. The fiber distribution in the micropillar was obtained from a specimen manufactured for real micropillar mechanical testing. Based on the failure modes directly observed from the micropillar testing, the RVE model aims to capture the major failure mechanism, which is the fiber/matrix interface failure of the composite. In the finite element model, the properties of each individual phase, namely, the fiber and the matrix are first identified. Then, cohesive elements are incorporated into the interphase region between the fiber and matrix to capture the interphase debonding. Finally, the global stress–strain relation of the composites is obtained and compared to experimental results. A good correlation was found. Due to convergence difficulties associated with stiffness degradation, the simulation was performed in the commercial software ABAQUS/Explicit. A Molecular dynamics simulation is performed to investigate the stress–strain relation and shear strength of carbon fiber-reinforced polymer composites at nanoscale. The compressive strength and stiffness obtained from MD simulation were lower than that observed from experiments. Interface debonding is a critical failure mode, of which the failure strength is determined from fiber pull-out simulation. The results can be used in RVE simulation to deduce the interphase properties. The modeling method allows the detailed failure mechanisms of the composite microstructure to be captured and a correlation between the micro-properties and macro-properties of the material to be established.

Tool wear influence on surface roughness, burrs and cracks in milling unidirectional carbon fiber reinforced plastics (UD-CFRP)

This study delves into the machining defects encountered during the milling of Carbon Fiber Reinforced Plastics (CFRP), with a special focus on fishbone-like cracks on the machined surface, which have never been focused before. Through a series of experiments, models for post-machining fiber burrs and matrix cracks were developed and analyzed, uncovering the causes of fishbone crack formation. The research reveals that the formation mechanisms of burrs vary with fiber orientation, burrs are not only from fiber bending under tool pressure but also from fiber buckling. Fishbone cracks are believed to be induced by growing burrs as the tool wear, and propagate along the in-plane and subsurface. Propagation downwards is along the fiber direction, while propagation inward is at an angle of approximately 40° ± 3°. This research is vital for enhancing the machining quality of composite materials and their engineering applications.

Measuring the in-plane thermal diffusivity of anisotropic solids by lock-in infrared thermography: Laser-spot vs laser-line heating

A method is proposed to measure the in-plane thermal diffusivity of anisotropic solids along an arbitrary direction using laser-line lock-in thermography. In this method, the sample is heated by an intensity-modulated laser beam, which impinges on the sample surface with the shape of a narrow strip. The resulting temperature oscillations are recorded by a thermographic camera and a phase thermogram is obtained by lock-in processing the image sequence. The thermal diffusivity along the direction perpendicular to the laser line can be determined from the linear dependence of phase lag with the distance to the heating line using the slope method. Unlike laser-spot lock-in thermography, in which the slope method only provides the thermal diffusivity along the principal directions, in this configuration, the thermal diffusivity can be measured experimentally along any direction, just selecting the relative orientation of the sample with respect to the laser line. Moreover, this configuration allows averaging several parallel phase profiles leading to more reliable thermal diffusivity values. The experimental results are presented for a highly anisotropic material, namely, a unidirectional carbon fiber-reinforced polymer plate.

A Comprehensive Study on the Optimization of Drilling Performance in Hybrid Nano-Composites and Neat CFRP Composites Using Statistical and Machine Learning Approaches

Carbon fiber-reinforced polymer (CFRP) composites have gradually replaced metals due to their exceptional strength-to-weight ratio compared to metallic materials. However, the drilling process often reveals various defects, such as surface roughness, influenced by different drilling parameters. This study explores the drilling quality of uni-directional CFRP composites, as well as hybrid Al2O3 alumina and hybrid SiC silicon carbide nano-composites, through experimental exploration using step, core, and twist drills. Response surface methodology (RSM) and statistical tools, including main effect plots, ANOVA, contour plots, and optimization techniques, were used to analyze the surface roughness of the hole. Optimization plots were drawn for optimal conditions, suggesting a spindle speed of 1500 rpm, feed of 0.01 mm/rev, and a 4 mm drill diameter for achieving minimum surface roughness. Furthermore, two machine learning models, artificial neural network (ANN) and random forest (RF), were used for predictive analysis. The findings revealed the robust predictive capabilities of both models, with RF demonstrating superior performance over ANN and RSM. Through visual comparisons and error analyses, more insights were gained into model accuracy and potential avenues for improvement.

Axial compression tests on CFRP strengthened CFS plain angle short columns

A comprehensive test program was performed to experimentally investigate the effect of CFRP strengthening on the axial strength and stability of CFS plain angle short columns subjected to monotonic axial compression. A total of 28 specimens were tested by varying the CFRP strengthening configurations for different column heights. Both uni-directional (CF_UD) and bi-directional (CF_BD) CFRP were considered. The influence of various parameters such as the type of CFRP, fiber orientation, and number of CFRP layers was investigated and discussed in detail. For single layer (ply) of CFRP, CF_UD-0° strengthening configuration resulted in maximum increase of axial capacity by 58.33% and 45.72% (in comparison to bare steel specimens), corresponding to 0.5 m and 1.0 m column lengths respectively. All the bare steel and skin-strengthened specimens failed predominantly due to torsional–flexural buckling mode. Additional layer of CFRP wrapping was found to enhance the axial capacity further and CF_UD-0°/BD was found to possess greater capacity in the case of double layer of CFRP. Adopting cardboard in-fill in addition to CF_UD-0° wrap has prevented the torsional mode of buckling and resulted in a peak increase of axial capacity by 192.55% and 240.61% corresponding to 500 mm and 100 mm long specimens, respectively.

Fracture Behavior of a Unidirectional Carbon Fiber-Reinforced Plastic under Biaxial Tensile Loads.

In order to clarify the fracture behavior of a unidirectional CFRP under proportional loading along the fiber (0°) and fiber vertical (90°) directions, a biaxial tensile test was carried out using a cruciform specimen with two symmetric flat indentations in the thickness direction. Three fracture modes were observed in the specimens after the test. The first mode was a transverse crack (TC), and the second was fiber breakage (FB). The third mode was a mixture mode of TC and FB (TC&FB). According to the measured fracture strains, regardless of the magnitude of the normal strain in the 0° direction, TC and TC&FB modes occurred when the normal strain in the 90° direction, εy, ranged from 0.08% to 1.26% (positive values), and the FB mode occurred when εy ranged from -0.19% to -0.79% (negative values). The TC&FB mode is a unique mode that does not appear as a failure mode under uniaxial tension; it only occurs under biaxial tensile loading. Biaxial tensile tests were also conducted under non-proportional loading. The result showed three fracture modes similarly to the proportional loading case, each of which was also determined by the positive or negative value of εy. Thus, this study reveals that the occurrence of each fracture mode in a unidirectional CFRP is characterized by only one parameter, namely εy.

Microstructure dependent transverse strength criterion for UD-CFRP composites via computational micromechanics and machine learning

The transverse strength of unidirectional carbon fiber reinforced polymer (UD-CFRP) composites is a high dimensional and nonlinear function of microstructure due to the wide scatter in mechanical properties and complex failure mechanisms, which is a challenging task to develop a general microstructure dependent strength criterion (MDSC) in theory or computation. Volume fraction and distribution of fibers are among the crucial influencing factors. A computational micromechanics and machine learning (ML) combined method is employed to uncover the transverse mechanical response of UD-CFRP composites. High-throughput finite element analyses (FEA) are performed to obtain the transverse behaviors of composites with varying fiber distribution and volume fraction under different loading states. They showed that fiber distribution has different effects on strengths in different failure modes, while the failure modes are closely related to loading states and fiber volume fractions. An ML model is then trained to characterize the relations between composite microstructure and composite strength. Then, the transverse strengths of 1000 new microstructures are predicted, which shows good agreement with FEA results, so that the MDSC of UD-CFRP is constructed by fully accounting for the influence of fiber distribution. Reliability of the method is verified by considering composites with various fiber volume fractions.

A pre-screening of the solvolysis recycling process for CFRPs based on the mechanical properties of the recovered fibers.

Over the past few decades, composite materials, and specifically carbon fiber reinforced plastics (CFRPs), are finding increasing use in the automotive, aerospace, and aeronautics industries. As a result, the production of CFRPs has been significantly increased, thus leading to a corresponding increase in waste production. In the near future, landfill and incineration disposal of waste will likely be prevented due to legislation, thereby bringing forward the need to develop efficient recycling processes for CFRPs. However, recycling of CFRPs is very challenging, mainly due to the difficulty in removing the thermosetting matrix. This paper reports a pre-screening of the solvolysis recycling process for CFRPs on the basis of the mechanical properties of the recovered fibers. To this end, solvolysis tests were conducted on unidirectional CFRP samples under supercritical and subcritical conditions using acetone and water. The solvolysis tests were conducted for various conditions of temperature, pressure, and reaction time. The efficiency of the recycling processes has been evaluated by means of single-fiber tension tests on the recovered fibers, which were conducted according to the ASTM C 1557-14 standard. In most cases, the decomposition efficiency of the epoxy resin in the CFRP, measured in terms of mass, ranged between 90 and 100%. Moreover, the mechanical tests showed that the recovered fibers retained more than 58% of their initial Young’s modulus and tensile strength.

Optimization of drilling parameters on delamination and burr formation in drilling of neat CFRP and hybrid CFRP nano-composites

Carbon fibre-reinforced polymer (CFRP) composites have exceptional mechanical advantages such as high specific strength and stiffness, lightweight, and high damping capacity, making them very attractive for aircraft, aerospace, automotive, marine, and sporting applications. However, various defects such as delamination, burr formation, and surface roughness are observed during the drilling of CFRP composites, which are influenced by various drilling process parameters. In this work, the drilling quality of uni-directional CFRP composites. and the hybrid Al2O3 and hybrid SiC nano-composites are investigated experimentally using different types of drills such as step drill, core drill, and twist drill, as there is a limited study done on the comparative analysis of the impact of the above drills on the delamination factor and burr area on the above CFRP and hybrid nano-composites. The design of the experiment table was developed using response surface methodology (RSM) for input process parameters of spindle speed, feed, drill diameter, and drill type. The output surface characteristics (delamination factor and burr area) of the hole were measured quantitatively using the stereo zoom optical microscope. The main effect plots, contour plots, and analysis of variance (ANOVA) were used to examine the effect of spindle speed, feed, drill diameter, and drill type on exit delamination and burr formation. The analysis of main effect plots, contour plots, and analysis of variance showcased the optimum process parameters, such as a high spindle speed of 5500 rpm, low feed of 0.01 mm/rev, and drill diameter of 4 mm. The step drill demonstrated the least damage mechanism among drill geometries, followed by the twist and core drills. The minimum drilling damage was observed for the Al2O3 hybrid nano-composite compared to the neat CFRP composites.

Transmission Loss Analysis of Unidirectional Carbon Fiber-Reinforced Polymers for Millimeter Waves for Linear and Circular Polarization

Transmission Loss Analysis of Unidirectional Carbon Fiber-Reinforced Polymers for Millimeter Waves for Linear and Circular Polarization

CFRP strengthening of web perforated CFS lipped channel short columns: An experimental study

Web perforations provided in the columns or studs of light-gauge steel buildings to meet the functional requirements, decrease the axial capacity and lead to localized failure. Hence, the aim of this study is to experimentally investigate the influence of carbon fiber reinforced polymer (CFRP) strengthening on the stability, axial strength, and stiffness of the CFS web-perforated lipped channel short columns (of 600 mm length) subjected to monotonic axial compression. A total of 20 specimens, provided with circular perforation at mid-height and at the centre of the web, were tested by adopting different CFRP skin-strengthening configurations, considering Uni-Directional CFRP (CF_UD) and Bi-Directional CFRP (CF_BD) laminas or laminates. From the tests conducted, it was observed that CF_UD and CF_UD / UD were found to result in an increase in axial capacity of 11.12% and 22.23% for the cases of single- and double-layered CFRP, respectively. Similarly, the axial stiffness increased by 9.23% and 26.07%, respectively. However, the only considered triple-layered laminate, CF_UD / UD / BD has outperformed among the entire adopted strengthening configurations, with an increase in axial strength and stiffness of 28.90% and 38.33%, respectively, in comparison to the bare steel specimens. Notably, a local-distortional interactive buckling mode of failure was noticed in the cases of both bare steel and CFRP-strengthened specimens.

Effect of polyurea coating on low-velocity impact properties of unidirectional carbon fiber-reinforced polymer composites plates

To improve the impact performance of unidirectional carbon fiber-reinforced polymer composites (CFRP) for engineering structures, a polyurea coating was sprayed on the CFRP surface. Effects of the polyurea spraying position and thickness on the CFRP impact properties were studied using a low-velocity impact test and computed tomography. The results show that the front-coated polyurea layer reduces the impact energy acting on CFRP because of the consumption of impact energy so that the internal damage of CFRP is smaller and retains higher CFRP bearing capacity than that of other spray positions. The rear-coated polyurea layer has a supporting effect on CFRP, thus the plastic deformation of CFRP is reduced and the structural integrity of CFRP is maintained. Under the impact load, the damage mainly occurred inside the CFRP, and almost no damage occurred in the polyurea layer. The damage in CFRP is mainly the split along the fiber direction, and it is trapezoidal and delaminated from the impact surface to the back-impact surface.

A Preliminary Investigation on a Water- and Acetone-Based Solvolysis Recycling Process for CFRPs.

Composites, and especially carbon-fiber-reinforced plastics (CFRPs), are increasingly used in the automotive, aerospace, and aviation industries, and as a result, CFRP production has increased dramatically, leading to a corresponding increase in waste. Landfills and the incineration of waste are likely to be restricted as a result of legislation, thus highlighting the need for efficient recycling methods for CFRPs. However, the recycling of CFRPs is very challenging, mainly due to the difficulty of removing their thermosetting matrix. This study reports a pre-screening of the solvolysis recycling process for CFRPs based on the mechanical properties of the recovered fibers. To this end, solvolysis tests were conducted on unidirectional CFRP samples under supercritical and subcritical conditions using acetone and water. The solvolysis tests were conducted for various conditions of temperature, pressure, and reaction time, without the use of any catalyst. Also, the loading rate (volume of solvent/volume of reactor) was constant. The efficiency of the recycling processes has been evaluated through a morphological and a mechanical characterization of the recovered fibers. In most cases, the decomposition efficiency of the epoxy resin, measured in terms of mass, ranged between 90 and 100%. Moreover, the scanning electron microscopy images of the recovered fibers showed negligible traces of resin residues and no detectable signs of physical damage or any changes in morphology with regard to diameter. Finally, the single-fiber tension tests revealed that that the recovered fibers retained more than 61% of their initial Young's modulus and 70% of their tensile strength.

Ultrasonic cavitation erosion of CFRP composites

To date, cavitation erosion of carbon fibre reinforced polymer (CFRP) composites has attracted only limited scientific attention. This paper investigates this knowledge gap through a series of experiments, in which unidirectional and bidirectional (2x2 twill) CFRP composites were exposed to cavitation clouds produced by an ultrasonic transducer in distilled water. Both composites were bonded with epoxy resin. Cavitation erosion tests were conducted according to the ASTM G32-16 standard using a stationary specimen method. The effect of water absorption on monitoring erosion damage was studied using saturated and dry specimens. Specimen mass loss measurements and microscopy observations were done at regular intervals throughout testing. Erosion imprint topographies were studied using X-ray computed microtomography. Three distinct erosion stages were identified from the erosion process observations. Nonuniformities in surface geometry and properties facilitated nucleation and accelerated local erosion. Surface epoxy thickness, fibre diameter and packing, and thickness and layup of fibre bundles influenced the erosion process. The erosion mechanisms included cracking and debonding of epoxy, and tunnelling and trenching in fibre bundles. Research findings indicated that the composite internal structure can potentially be designed for reduced water absorption and increased erosion resistance. Acoustic impedance was most efficient in predicting material response to cavitation erosion.

Experimental Comparative Analysis of the Through-Thickness and In-Plane Compression Moduli of Unidirectional CFRP Laminates

This study explores the experimental characterization of the through-thickness compression properties in unidirectional laminates using cube compression tests. Cubical specimens, each with an edge length of 10 mm, were symmetrically outfitted with biaxial strain gauges and subjected to a compression test. While similar methodologies exist in the literature, this work primarily addresses the potential biases inherent in the testing procedure and their mitigation. The influence of friction-induced non-uniform deformation behavior is compensated through a scaling of the stiffness measurements using finite element (FE) analysis results. This scaling significantly enhances the accuracy of the resulting parameters of the experiments. The ultimate failure of the specimens, originating from stress concentrations at the edges, resulted in fracture angles ranging between 60° and 67°. Such fracture patterns, consistent with findings from other researchers, are attributed to shear stress induced by friction at the load introduction faces. The key findings of this research are the comparisons between the through-thickness modulus (E33c) and strength (X33c) and their in-plane counterparts (E22c and X22c). The results indicate deteriorations of E33c and X33c from E22c and X22c by margins of 5% and 7%, respectively. Furthermore, the results for E22c and X22c were compared with the results obtained through a standard test, revealing a 12% enhancement in strength X22c and 4% underestimated stiffness E22c in the cube compression test.

Prediction of creep failure life for unidirectional CFRP with heat-resistant epoxy resin as matrix exposed to high temperature under tension load

The accelerated testing methodology (ATM) developed by the authors is the methodology for predicting statistically long-term life of CFRP structures based on the viscoelasticity including the time-temperature superposition principle for matrix resin. The formulae of ATM are expressed as the product of static strength at room temperature, its dispersion, and the viscoelastic parameter of matrix resin that changes with time and temperature history. This methodology ATM was applied to the prediction of long-term creep failure life for unidirectional CFRP with heat-resistant epoxy resin as matrix under heat degradation in this study. Resin impregnated CFRP strands with heat-resistant epoxy resin were molded using a filament winding system as virgin specimens of unidirectional CFRP. Then, heat-degraded specimens were prepared by exposing the virgin specimens under acceleration conditions determined based on the time-temperature superposition principle for chemical deterioration assuming the condition of practical temperature 110°C and period 10 years. Second, the creep strengths of virgin and heat-degraded CFRP strands were statistically predicted based on ATM and the effect of heat degradation on the long-term life of CFRP strands was evaluated. As results, it was cleared that when the creep strength of CFRP strands undergoes thermal aging at the practical condition, in addition to the strength decrease to time due to the viscoelasticity of the resin, a comparable decrease in static strength and increase in this scatter occur.

Enhanced Estimation of Axial Compressive Strength for CFRP Based on Microscale Numerical Simulation and the Response Surface Method.

Compressive strength is one of the most important properties of carbon fiber reinforced plastics (CFRP). In this study, a new method for predicting the axial compressive strength of CFRP using the response surface method is developed. We focused on a microbuckling model to predict the compressive strength of unidirectional fiber composites. For the microbuckling model, axial shear properties are required. To obtain the compressive strength for various material properties, we perform individual shear tests and numerical simulations, but these require enormous computational costs and extended time. To address the issue of computational cost, in this study, we propose a new method to predict compressive strength using the response surface method. First, we perform shear simulation in a microscale fracture model for unidirectional CFRP with various parameters of the fiber and resin properties. Based on the results of the shear simulation, the response surface method is used to evaluate and develop prediction equations for the shear properties. This method allows for the study of the objective values of the parameters, without significant computational effort. By comparing both the results predicted from the response surface method (RSM) and the simulation results, we verify the reliability of the prediction equation. As a result, the coefficient of determination was higher than 94%, and the validity of the prediction method for the compressive strength of CFRP using the response surface method (RSM) developed in this study was confirmed. Additionally, we discuss the material properties that affect the compressive strength of composites comprised of fibers and resin. As a result, we rank the parameters as follows: fiber content, elastic modulus after resin yield, yield stress, and initial elastic modulus.

Experimental Investigation on the Rehabilitation of RC Flat Slabs Using CFRP Sheets to Enhance Punching Shear Capacity

In this paper, the feasibility of strengthening a flat column–slab connection within the carbon fiber reinforced polymer (CFRP) has been investigated through experimental study. The experimental program includes a set of nine reinforced concrete flat slab specimens. Three unaltered specimens served as control slabs, while an additional six samples were strengthened with various CFRP configurations to enhance their shear capacity. The strain distribution, ductility, punching shear resistance, stiffness, and crack formation were studied. The result of experimental studies showed that in the direct method of strengthening in which two layers of unidirectional CFRP sheets were employed in two opposite directions, the ultimate punching shear resistance improved by 64%, 44.7%, and 15.3%, with respect to the location of the column connection, as compared with the control specimens. In the case of using one layer of unidirectional CFRP strips, the punching shear resistance was enhanced by approximately 16% and 39%, considering the configuration of CFRP sheets and the amount of strengthened and adhesive layers used. Following the outcomes of this research, the application of CFRPs in improving the resistance capacity of flat slabs against the punching shear is considerable. The reported outcomes were compared with the latest provisions of ACI to show the efficiency of the presented strengthening. Finally, a parametric study was performed assuming different loading locations to assess the effect of the loading region on the response of RC slabs. Results indicate that approaching the loading location toward the RC slab supports results of an increase in the load-bearing capacity and a reduction in the ductility of the RC slab.