Woven Fabric Composites Research Articles

General method to digitalize multi-layer woven structure

As an advanced composite reinforcement, multi-layer woven fabrics are widely used in industries. However, for most nonprofessional engineers and researchers, the complexity of the spatial architecture of multi-layer woven structure (MLWS) makes it difficult to understand and apply. In order to fully utilize the advantage of the designability of MLWS, a digitalization expression is used to define the design variable of MLWS by 8 parameters. This expression has wide universality and practicability, which can parametrize all kinds of MLWSs, and characterize full-scale complex preforms. Based on this expression, a general method and process for constructing novel and complex MLWS architectures are also proposed and developed. Furthermore, a method to generate the preform jacquard pattern for the electronic jacquard system is also developed to demonstrate the application in manufacturing. This digitalization expression can be considered as the key point to connect the material design and automatic manufacturing, which can improve the design technology of multi-layer woven composite material.

Optimization of Uniaxial Tensile Stress-Strain Response of 3D Angle Interlock Woven Fabric Composite using Weft Density and Draw-In Plan Variables

Currently, 2D woven composites are extensively incorporated into a variety of technical automotive body parts and protective body armor owing to their excellent fabric strength performance. However, there is still a lack of attempts to utilize 3D woven fabrics for the same technical application. Hence, it is vital to examine the fundamental tensile strength of woven fabric composite materials when determining their suitability for end-use applications. This study aimed to investigate the novel effects of two parameters on the uniaxial tensile strength of a high-tenacity polyester three-layer 3D angle interlock (3DAI) woven fabric composite, namely, weave drafting draw-in insertion and weave density. Four different drafting patterns were considered: pointed (DRW 1), broken (DRW 2), broken mirror (DRW 3), and straight (DRW 4), for weft density at 14 and 25 pick.cm-1. Samples of the 3DAI woven fabric reinforced with epoxy composite at different drafting patterns and weft density combinations were produced and tested. Consequently, the maximum tensile stress and strain were recorded in the woven fabric composite sample with DRW 4 and 25 pick.cm-1 at 113 MPa and 11%, respectively. The study shows that different weft densities and draw-in plan settings play a significant role in the tensile strength performance of the 3DAI woven composite.

Studies on the stab resistance and ergonomic comfort behaviour of multilayer STF-treated tri-component woven fabric and HPPE laminate composite material

Research related to stab-resistant armour is focused on developing a low-weight flexible stab-resistant armour. Various materials and methods have been used to reduce the overall bulk but managing the flexibility and bulk with improved stab resistance is still a challenge for the researchers. In this study, flexible stab-resistant material for stab-resistant personal protective equipments (PPEs) has been developed by using shear thickening fluid (STF) treated fabric made of multicomponent yarns and ultra high molecular weight polyethylene (UHMWPE) laminate composite. The stab resistance and comfort behaviour like flexural rigidity and areal density were investigated with respect to number of layers and different STF concentrations according to VPAM KDIW-2004 and respective standards for flexural rigidity. Laminate-Woven hybrid composite was developed to reduce the bulk of the panel while maintaining the required protection level.

The through-thickness thermal conductivity and heat transport mechanism of carbon fiber three-dimensional orthogonal woven fabric composite

This paper successfully constructed a high through-thickness thermal conductivity carbon fiber composite with three-dimensional orthogonal woven fabric (3DOWF) by taking advantage of the high conductivity of carbon fiber. The effect of structural parameters and Z-direction bundling yarn (Z-yarn) on thermal conductivity (TC) was investigated, and thermal transport mechanism was analyzed. The results show that the TC in the through-thickness direction of 3DOWFs increase dramatically after adding Z-yarn structure, reaching up to 4.12 W/m/K, which is 116% higher than the laminated sample. A plane heat source was established to record the temperature-time curves of the composites, and results show that the composites with higher TC have faster equilibrium time and higher equilibrium temperature. Infrared thermography demonstrates the difference of thermal response process between 3DOWF and laminated material. To sum up, a large amount of heat energy can be transferred rapidly from hot surface to cold one through these Z-yarn paths in the thermal conductive network of 3DOWF, which has potential application in composite with high thermal conductivity.

Assessment of a unique reinforcement construction on mechanical behaviour of composite structures

The construction type of reinforcement material is a critical factor playing an essential role in the mechanical performance of composite materials. Recently, much attention has been attracted to discovering the mechanical behaviour of glass woven fabric, such as plain and different variations of twill and satin reinforced composites. In this paper, it is aimed to test the effect of a combination of unique characteristics of woven and knitted fabrics in the same matrix on the mechanical behaviour of composites. In this direction, carbon tows are fabricated into plain woven, 2/2 twill woven and interlock knitted fabrics. The effect of reinforcement construction on bending and tensile properties like strength, modulus and strain of epoxy composites manufactured in three variations as woven, knitted and woven/knitted reinforced was investigated by conducting 3-point bending and tensile tests. Experimental results indicated that hybrid composites displayed lower bending strength than woven fabric composites. However, a combination of 2/2 twill woven and knitted fabric in hybrid composites, including five fabric layers, had a higher bending modulus than 2/2 twill woven composites, including seven fabric layers. Also, it was observed that the mechanical performance of hybrid composites under tensile load was poor compared to the woven fabric composites.

Inverse Identification and Design of Thermal Parameters of Woven Composites through a Particle Swarm Optimization Method

Designing thermal conductivity efficiently is one of the most important study fields for taking the advantages of woven composites. This paper presents an inverse method for the thermal conductivity design of woven composite materials. Based on the multi-scale structure characteristics of woven composites, a multi-scale model of inversing heat conduction coefficient of fibers is established, including a macroscale composite model, mesoscale fiber yarn model, microscale fiber and matrix model. In order to improve computational efficiency, the particle swarm optimization (PSO) algorithm and locally exact homogenization theory (LEHT) are utilized. LEHT is an efficient analytical method for heat conduction analysis. It does not require meshing and preprocessing but obtains analytical expressions of internal temperature and heat flow of materials by solving heat differential equations and combined with Fourier's formula, relevant thermal conductivity parameters can be obtained. The proposed method is based on the idea of optimum design ideology of material parameters from top to bottom. The optimized parameters of components need to be designed hierarchically, including: (1) combing theoretical model with the particle swarm optimization algorithm at the macroscale to inverse parameters of yarn; (2) combining LEHT with the particle swarm optimization algorithm at the mesoscale to inverse original fiber parameters. To identify the validation of the proposed method, the present results are compared with given definite value, which can be seen that they have a good agreement with errors less than 1%. The proposed optimization method could effectively design thermal conductivity parameters and volume fraction for all components of woven composites.

Investigation on Layer Hybridization of Glass/Carbon Fibre Woven Reinforced Composites Subjected to Low-Speed Impact

The present investigation was conducted on the low-speed impact response of quasi-isotropic [±45/0/90°]xs hybrid composite through laboratory level experimental tests. The purpose was to understand the behaviour that the different stacking sequences of hybrid glass/carbon fibre composites has on the ability of the material to sustain loads during low-speed impact events without developing critical structural failure in the material and improving the impact energy absorption properties, which is a relevant matter in aerospace and automotive industries. Drop-weight impact tests were carried out on two different laminates, with different stacking sequences, each of which were 16 symmetric inter-ply hybrid laminates named GC [+45G/−45C/0G/90C]4s and, respectively, G-C [+45G/−45G/0G/90G/+45C/−45C/0C/90C]2s, where G stands for glass fibre and C for carbon fibre. Both were comprised of epoxy matrix reinforced carbon/E-glass fibre woven fabric composites. The outcome of changing the hybrid stacking sequence, on the impact performances, was discussed. The damage morphologies and local failure mechanisms were analysed using visual inspection and a high-resolution laser scanner. Under 33 J impact energy, both tested hybrid composites exhibited approximately 10 kN peak load. Nevertheless, one key parameter, the time to peak load, significantly changed; the damage initiation threshold for GC samples occurred immediately before 6 kN, whereas for G-C samples this threshold appeared much earlier. This type of behaviour was partly connected to the delay in the propagation of delamination and fibre breakage, which was influenced by the high elastic energy absorption of the carbon fibres when compared with the glass fibres. The absorbed energy was higher for GC configuration, whereas a higher DI was observed for samples G-C indicating that a high percentage of the total energy was dissipated through the propagation of in-plane and out-of-plane fibre/matrix cracks. No perforation was observed on either configuration; nevertheless, the damage area significantly changed both in size and appearance from one configuration to another.

Assessment of tensile behaviour of plain weave fabric CFRP composites using acoustic emission technique and deep learning

The applications of Carbon Fibre Reinforced Plastic (CFRP) composites in aerospace applications have increased exponentially in the last decade. CFRP composites are now replacing conventional materials used in high temperature applications. Different types and strategies of reinforcements are used in these composites to improve their applicability to high temperature applications. One of the reinforcement strategies that has been used frequently in the recent years is the plain weave fabric configuration of reinforcing fibres in polymer matrix. A comprehensive damage assessment is essential to evaluate the characteristics of these composites at elevated temperatures. The Acoustic Emission (AE) signals generated during the damage evolution stages are used for studying the damage evolution stages when the plain weave fabric composites are tested at temperatures close to their glass transition state. A new information-theoretic parameter, Lempel-Ziv (LZ) complexity and the deep learning neural network is used for understanding the damage evolution stages. Furthermore, the neural network is used for validating the utilization of LZ complexity as a potential AE parameter for damage classification applications. The results are promising with the damage classification strategy using LZ complexity exhibits an accuracy of 85.1% which is validated through the neural network.

Effect of fiber hybridization on tensile fracture of 3D woven textile composites

3D Woven composites provide the ability to handle higher damage tolerance (Pankow et al., 2019). Hybridization of fibers is an additional method to provide improved damage tolerance (Pankow et al., 2014) . This work is the first time that the tensile response of “hybrid” 3D woven composites (H3DWC) is investigated. The hybridization showed an increase in modulus with increasing carbon fiber volume fraction ( > 30 % in general). While, the strength showed a decrease that was proportional to the carbon fiber volume fraction ( > 78% of the baseline glass). Although the carbon failed, the material remains intact as the glass fibers have not failed, maintaining 80% of the strength after failure in the warp direction. The unsymmetric samples, which have benefits for bending type loading, produced coupled behavior due to thermally induced shrinkage. Overall looking at the combination of factors from previous bending work with this new tensile work, it can clearly be seen that there is a clear tradeoff in the amount and way one would perform hybridization.

Enhanced thermographic inspection of woven fabric composites by [formula omitted]-space filtering

Infrared thermography is a well-known non-destructive testing technique for detecting defects in unidirectional fiber reinforced polymer laminates. When applied to woven fabric reinforced polymers, however, the weave structure causes strong disturbances and patterns in the background of the thermal images, making accurate and reliable defect assessment a challenging task. In this paper, the concept of k-space filtering is introduced for an improved evaluation of thermographic images obtained from woven fabric composites. An algorithm is introduced to automatically decompose a thermographic image into an image which contains the structured thermal background related to the weave pattern, and a residual image representing other features, e.g. defects. The proposed k-space filtering approach is demonstrated on thermographic data from various woven fabric composites with different weave patterns and defect scenarios, clearly showing an enhanced performance in terms of defect detection and sizing.

Ancient papyrus scroll-inspired self-deployable mechanism based on shape memory polymer composites for Mars explorations

Mars has similar natural environments to Earth and is regarded as a potential candidate for human migration. Exploration to Mars has been a hotspot in major aerospace countries, and therefore bringing the national flag to Mars is an inevitable demand. A self-deployable mechanism inspired by the ancient papyrus scroll to demonstrate the national flag dynamically is proposed in this paper. The release device made of shape memory polymer composites, as the functional part, is analysed thoroughly from the perspective of material design, fabrication and experiments. Firstly, the mechanical properties of woven fabric composites are predicted theoretically, and the thickness of laminates is determined according to the mechanical requirement, fabrication technique and shape moulding method. Tensile and three-point bending tests were carried out to validate the analytical prediction and provide parameters for numerical simulation. Besides, shape fixation and recovery properties were studied by both simulation and experiments with consistent results. Additionally, the shape moulding method was modified by reheating and sustaining a high-temperature period after bending to obtain the designed pattern. This world’s first application of shape memory polymer composites in Mars explorations is a milestone for both deep space exploration and advanced smart materials.

Exploring the Elastic Properties of Woven Fabric Composites: A Machine Learning Approach for Improved Analysis and Design

Woven fabric reinforced plastic composites are highly favoured in the aerospace and automotive industries for their exceptional impact resistance and ease of manufacture. To design and analyse these structures, it is crucial to determine their elastic properties of woven fabric composites, which can be estimated through analytical, numerical, or experimental means. In this study, we propose a novel approach that combines machine learning techniques with finite-element methods based multi-scaling analysis methodology to predict the elastic behaviour of woven composites. The method leverages datasets generated from finite element methods based numerical simulations and literature to train and validate models, providing a cost-effective and computationally efficient alternative to conventional homogenization-based finite element method. The approach offers a promising solution to accurately predicting the elastic behaviour of woven fabric composites.

Elastic properties and strength criterion of reinforced composite

Woven composite materials are increasingly being used in various fields of modern technology. Unlike composites reinforced with straight fibers, they have a higher shear stress loading strength and improved impact strength characteristics. Woven composites have good technological properties. Blanks with carbon or glass fabrics are well laid out on tooling in the manufacture of thin-walled structural elements of complex shapes. The technological advantages of woven composite materials have determined the economic feasibility of their widespread use in the aviation industry and the automotive industry. The paper presents a numerical method for identifying the elastic and strength characteristics of woven carbon fiber based on the results of a micromechanical analysis of a representative volume based on the known properties of the matrix and fibers. Numerical experiments on uniaxial tension in the x, y, and z axes directions have been carried out. Modeled shift in three coordinate planes. The strength characteristics of the representative volume of the composite under conditions of tension and compression in three directions, shifts in three planes, and three biaxial tensions are determined.

Predicting the tensile stiffness and strength properties of plain woven carbon fiber/epoxy laminates: a practical analytical approach and experimental validations

The difficulties in establishing an analytical model for plain woven fabric composites (PWFC) and its implementation are well-accepted due to the complexity of yarn architecture, approximations assumed, and lack of experimental validations. In this paper, a practical engineering approach is proposed to predict the tensile properties of PWFC. The approach assumes PWFC as cross-ply, the undulation angle an elliptical shape. The approach tremendously simplifies the calculation keeping a close agreement with the tensile experimental results of PWFC. The approach is remarkably compatible with other theoretical models and experiments that existed in the literature.

Highly tough 3D woven composite materials: Fracture characterization and toughening mechanisms

Characterization of the intralaminar fracture toughness of 3D woven composites is challenging owing to the limitation of linear elastic fracture mechanics-based approach. In this study, five different crack configurations are designed and tested. Only the single-edge notched tensile specimen can be used to measure the fracture toughness. A hybrid approach based on experiment and cohesive zone model is proposed to determine the R-curve of 3D woven composites. The fracture toughness of the present 3D woven composite is around 860 kJ/m2, considerably higher than those of the existing carbon fiber polymer reinforced composites. The mechanism underlying this high toughness is clarified.

Effects of impactors’ shape on three-dimensional woven fabric composites at low-velocity impacts

This study investigated the fabric resistance of three-dimensional (3D) woven fibreglass composites generated by impactors of three shapes, i.e., hemispherical, conical, and ogival, on four types of composite structures. Composites were fabricated using the hand lay-up technique. Crimp and mechanical impact resistance tests were carried out in accordance with ASTM D2444 standards and ASTM D3883-04, respectively. The four-floating interlocked (4FLL) yielded the strongest fabric damage tolerance for all the three types of impactors’ shapes with 6.3 kN for the hemispherical shape, 4 kN for the conically shaped, and 3.8 kN for the ogival shape. Additionally, the 4FLL generated a fabric crimp of 3.5% and 2.8% on both fabric directions. The post-impact damage showed that the ogival shape impactor penetrated samples of woven composites better than the conical and hemispherical shapes.

Water absorption behavior of the woven bamboo fabric polypropylene-based composites and their hybrids with glass

The high prone behavior towards water absorption is considered as a major weakness of natural based-fiber composites or bio-composites. These composites can be susceptible to considerable water absorbed due to hydrophilic nature of bamboo fiber, which may affect to degradation of their strength and stiffness performances. The effect of the hybridization is investigated with the study of water immersion at 23 °C and 60 °C, for a period of 70 days. It was shown that the composite’s absorption behavior demonstrated the kinetics behavior and classification proposed by Fick’s theory. There was a 142 % increase in the diffusion coefficients of samples immersed at 60 °C compared to those at 23 °C for BPP composites. The water absorption of BPP composites at 23 °C after 1680 h was approximate of 14.6 %, with the absorption was quite rapid initially, reaching almost 13.01 % after about 720 h. For the hybrid composites of 30B:20G, 20B:35G and 10B:45G for water absorption at 23 °C was reaching almost 10.56 %, 7.30 %, and 2.81 % respectively after 720 h. Furthermore, the composites approached equilibrium faster at 60 °C than at 23 °C. The absorption rate was significantly higher at 60 °C, with 80 % of the total absorption in the first 14 days, while the BPP composites at the immersion of 23 °C, reached equilibrium in the first 30 days. Similar behavior was also observed for the hybrid composites, reached almost 80 % of the total absorption in the first 7 days, when compared with 20 days for the hybrid composites. The presence of external plies of glass effectively decelerates water diffusion into the bamboo polypropylene (BPP) composites. The findings denote a significant observation in which, by substituting few layers of glass with woven-based bamboo in glass-polypropylene composites, offering to a hybrid concept to be possible for developing an alternative, excellent and better performance of light-weight composite.

Investigation of the effects of nanoparticle reinforcement on the mechanical properties of woven composites

AbstractNanoparticles are used in many areas related to composite materials. Recently, the importance of nanoparticle‐reinforced materials in advanced technology has been gradually increasing. In this study, epoxy reinforced with various nanoparticles, and neat epoxy were used to produce woven composites. The fatigue behaviors of woven composites reinforced with various nanoparticles under tension‐compression fatigue loads were investigated. The tensile and fatigue strengths of woven composites enhanced with nanoparticles were compared with woven composites without nanoparticles. Tensile tests showed that the woven composites reinforced with nanoparticles were damaged at high loads. Fatigue tests revealed that the woven composites reinforced with nanoparticles exhibited high cycle numbers. Adding 0.5%, 1%, and %3 nano‐CuO to epoxy increased the cycle numbers of the woven composites by 25%, 67%, and 75% respectively at 60% load level. The failure mechanisms of woven type composite materials were investigated by scanning electron microscopy (SEM). Fiber fractures and delamination damages of samples were observed.

The effect of different fillers, loads, and sliding distance on adhesive wear in woven e-glass fabric composites

In this study, adhesive wear of woven E-Glass fabric reinforced composites filled with aramid, B4C and mica particles at 0.5% wt. and 1.5% wt. ratios were carried out under dry sliding conditions. The effects of filler type, applied loads (5, 10 and 15 N) and sliding distances (250, 500 and 750 m) on the tribological behavior of the composites were investigated on the pin-on-disc device. As a result of the studies, it was determined that the friction coefficient in aramid reinforced composites was lower than the other reinforced composites. In wear volume due to wear, it was observed that the aramid wear volume was less. In addition, Wear volume increased with increasing load for all particle reinforcements. But, the highest wear volume occurred in the neat wear sample at 15 N load conditions. For the wear rate and wear volume, the fillers have shown improvement up to 1.5% wt. in the composite. 1.5% wt. aramid-filled glass fiber woven composites showed the lowest wear rate: 2.82 × 10−4 mm3/N-m (at 15 N normal load). In addition, in the scanning electron microscope images taken, it was observed that there were breaks in the size of 15.07 µm in the epoxy and 61.11 µm in the fibers. The use of aramid with particle reinforcement rather than fiber is important for wear. In addition, the lowest wear volume was 65% more resistant at 1.5% wt aramid reinforcement and at 15 N load compared to the unreinforced composite in the abrasion tests.

Chemical Behavior of Water Absorption in a Carbon/Epoxy 3D Woven Composite

AbstractIn this paper, moisture absorption of carbon/epoxy‐amine 3D woven composite materials is studied by immersion in distilled water at 70°C. If the moisture uptake measured by gravimetry is slow and weak over time, various antagonistic phenomena appear. Desorption highlights mass losses due to chemical changes in the material that mask the true water content of the aged samples. The X‐ray photoelectron spectrometry (XPS) reveals a decrease in the carbon and nitrogen proportions and an increase in the oxygen proportions after ageing, allowing to observe surface erosion and oxidation of the matrix. Finally, the rise of silicon is a sign of extraction of the silica‐based particles exuded to the surface. This presence is confirmed by Fourier transform infrared spectroscopy (FTIR).