Development of rubberized syntactic foam

This study explored a novel hybrid syntactic foam for composite sandwich structures. A unique microstructure was designed and realized. The hybrid foam was fabricated by dispersing styrene–butadiene rubber latex coated glass microballoons into a nanoclay and milled glass fiber reinforced epoxy matrix. The manufacturing process for developing this unique microstructure was developed. A total of seven groups of beam specimens with varying compositions were prepared. Each group contained 12 identical specimens with dimensions 304.8 mm × 50.8 mm × 15.2 mm. The total number of specimens was 84. Among them, 42 beams were pure foam core specimens and the remaining 42 beams were sandwich specimens with each foam core wrapped by two layers of E-glass plain woven fabric reinforced epoxy skin. Both low velocity impact tests and four-point bending tests were conducted on the foam cores and sandwich beams. Compared with the control specimens, the test results showed that the rubberized syntactic foams were able to absorb a considerably higher amount of impact energy with an insignificant sacrifice in strength. This multi-phase material contained structures bridging over several length-scales. SEM pictures showed that several mechanisms were activated to collaboratively absorb impact energy, including microballoon crushing, interfacial debonding, matrix microcracking, and fiber pull-out; the rubber layer and the microfibers prevented the microcracks from propagating into macroscopic damage by means of rubber pinning and fiber bridge-over mechanisms. The micro-length scale damage insured that the sandwich beams retained the majority of their strength after the impact.     

Characterization of thermoplastic natural fibre composites made from woven hybrid yarn prepregs with different weave pattern

This paper focuses on the effect of weave structure on mechanical behaviour and moisture absorption of the PLA/hemp woven fabric composites made by compression moulding. The unidirectional woven fabric prepregs were made from PLA (warp) and PLA/hemp wrapped-spun hybrid yarn (weft) with two different weave patterns; 8-harness satin and basket. Unidirectional composites with 30 mass% hemp content were fabricated from these prepregs, and compared to winded PLA/hemp hybrid yarn laminates with same composition. The composite from the satin fabric had significantly lowest porosities and best mechanical properties compared to the composite made from the winded hybrid yarn and basket fabric. The tensile, flexural, and impact strength were 88 MPa, 113.64 MPa, and 24.24 kJ/m², respectively. The effect of weave pattern on water absorption is significant. Although the composite from hybrid yarn laminate has larger water absorption than that of the pure PLA, it exhibits lower moisture absorption than both weaves.     

A novel fiber treatment applied to woven jute fabric/vinylester laminates

In this work, a novel fiber treatment consisting on an alkali treatment superimposed to biaxial tensile stress was successfully applied to woven jute fabric/vinylester laminates. The effect of treatment on the composites tensile properties was investigated at two different times of treatment. A significant improvement in stiffness was achieved by the composite treated with alkali under stress for 4 h. However, no significant differences between the stiffness of the untreated composite and the composites treated with alkali under stress for 24 h were found. On the other hand, irrespectively of the time of treatment, the composites with fabrics treated with alkali under stress showed the highest values of tensile strength. From results of fabrics tensile tests, compression shear tests and X-ray diffraction analysis, the improved tensile properties exhibited by the composites with treated fabrics could be attributed to structural changes of the fibers as well as to a change in the fiber/matrix interfacial properties.     

Effects of glass–fiber composite,dowel, and minifix fasteners on the failure load of corner joints in particleboard case-type furniture

In this study, effects of fasteners on the failure loads of L-type corner joints in laminated particleboard (LPB) case-type furniture have been analyzed experimentally and statistically. Glass–fiber composite (fabric), dowel, and minifix as fasteners and glass–fiber composite (C), dowel (D), dowel + fabric (DC), dowel + minifix (DM), and dowel + minifix + fabric (DMC) as joint type are used in this study. Tests were carried out according to ASTM Standards. Results show that the failure load takes its highest value in the DMC case for both average values of the test results and for 95% reliability under Weibull distribution. On the other hand, it takes its lowest value in the D case for compression test and in the C case for tension test. In addition, the 95% reliability values for each corner joint configuration are approximately equivalent to the 0.52 average value of the failure load.     

Effects of steam environment on creep behavior of Nextel™720/alumina–mullite ceramic composite at elevated temperature

The tensile creep behavior of an oxide–oxide continuous fiber ceramic composite was investigated at 1000 and 1100 °C in laboratory air and in steam. The composite consists of a porous alumina–mullite matrix reinforced with laminated, woven mullite/alumina (Nextel?720) fibers, has no interface between the fiber and matrix, and relies on the porous matrix for flaw tolerance. The tensile stress–strain behavior was investigated and the tensile properties measured. Tensile creep behavior was examined for creep stresses in the 70–140 MPa range. The presence of steam accelerated creep rates and dramatically reduced creep lifetimes. The degrading effects of steam become more pronounced with increasing temperature. At 1000 °C, creep run-out (set to 100 h) was achieved in all tests. At 1100 °C, creep run-out was achieved in all tests in air and only in the 87.5 MPa test in steam. Composite microstructure, as well as damage and failure mechanisms were investigated.     

Dielectric properties of woven fabric glass fiber reinforced polymer-matrix composites in the THz frequency range

Electromagnetic wave transmittances of plain woven fabric glass fiber reinforced epoxy matrix composite (PW-GFRP) and eight-harness-stain fabric glass fiber reinforced polyimide matrix composite (8H-GFRP) with 1.0 mm thickness were measured in a terahertz (THz) frequency range. The transmittance values for both composites are nearly zero at a frequency of 1.0 THz. The real parts of the complex dielectric constant, ε′(ω) are 4.45 and 3.87 for PW-GFRP and 8H-GFRP, respectively, in the frequency range from 0.2 to 1.0 THz, and they are almost frequency independent. Conversely, the imaginary parts of the dielectric constant, ε′′(ω) for both composites linearly increases with increase of the frequency from 0.13 to 0.37 for PW-GFRP, and from 0.12 to 0.33 for 8H-GFRP.     

Mechanical properties improvements in two-phase and three-phase composites using carbon nano-fiber dispersed resin

Static strength tests were carried out for cured carbon nano-fiber (CNF) dispersed resin as tow-phase composites and for CFRP laminates using CNF dispersed resin as three-phase composites. To obtain these CFRP laminates, the CNF dispersed resin was impregnated to CF reinforcement and cured by hot press. The CNF used was a cup-stacked type of nano-fiber, CARBERE^®, made by GSI CREOS Corporation, Japan. Two CNF aspect ratios of 10 and 50 were employed. These fiber lengths of the CNF were controlled about 1000 nm (AR10) and 5000 nm (AR50), respectively. The CNF was dispersed to EPIKOTE 827^® epoxy resin in two values of CNF weight ratios, 5 and 10% to the resin. TORAYCA^® C6343 plain woven fabric was used for reinforcement of the CFRP laminates. The cure condition with the agent of aromatic amine EPIKURE W^® was 100 °C for two hours followed by a post cure of 175 °C for 4 h. The static strength tests led to the conclusion that the dispersion of CNF into epoxy improves mechanical properties of the tow-phase composites, and that CFRP laminates with CNF dispersed resin also exhibit higher compressive strength than CFRP laminates without CNF as control. Possibilities of improvement in mechanical properties were confirmed in the two and three-phase composites. Moreover, a proportional tendency in strength improvements to CNF weight content was found in the two present composites so far in the present test results.     

Electromagnetic interference shielding of composites consisting of a polyester matrix and carbon nanotube-coated fiber reinforcement

We investigated the electromagnetic interference shielding effectiveness (EMI SE) of composites consisting of an unsaturated polyester matrix containing woven glass or carbon fibers that had been coated with multiwalled carbon nanotubes (MWCNTs). Composite panels consisting of fiber fabrics with various combinations of fabric type and stacking sequence were fabricated. Their EMI SE was measured in the frequency range of 30 MHz–1.5 GHz. The underlying physics governing the EMI shielding mechanisms of the materials, namely, absorption, reflection, and multiple reflections, was investigated and used in analytical models to predict the EMI SE. Simulation and experimental results showed that the contributions of reflection and absorption to EMI shielding is enhanced by sufficient impedance mismatching, while multiple reflections have a negative effect. For a given amount of MWCNTs in the glass-fiber–reinforced composite, coating the outermost, instead of intermediate, glass fiber plies with MWCNTs was found to maximize the conductivity and SE.     

Internal geometry of woven composite laminates with “fuzzy” carbon nanotube grafted fibers

Radially aligned carbon nanotubes (A-CNTs) grown on micron-scale fibers promise structural composites with high mechanical performance and multi-functional properties. Changes in the internal structure of woven composite laminates after A-CNT growth are studied here utilizing micro-computed tomography. The laminates are produced by vacuum impregnation in a closed mold with and without clamping pressure. Two A-CNT lengths are investigated: 4–6 μm and 17–19 μm. A-CNTs were found to increase the distance between fibers, scaled by the A-CNT length. This “swelling” resulted in an increased cross-sectional area, crimp and in-plane misalignment of the yarns. The laminate thickness doubled for laminates with long A-CNTs compared to shorter ones. The laminate with long A-CNTs produced under pressure showed a remarkable alteration of the internal structure. Fibers migrated within the fabric plane, filling almost completely the resin rich pockets. Further research is needed to understand the effect of these changes on the composite mechanical performance.     

Dedicated linear – Voce model and its application in investigating temperature and strain rate effects on sheet formability of aluminum alloys

This paper proposes a method to investigate the effects of temperature and strain rate on the forming limit curves (FLCs) by combining a modified Voce constitutive model (Lin-Voce model) with the numerical simulation of Marciniak test. The tensile tests are firstly carried out at different forming temperatures (20, 230 and 290 °C) and strain rates (2.5, 120 and 150 s⁻¹) for AA5086 sheet. A modified Voce constitutive model (named Lin-Voce model) is proposed to describe the deformation behavior of AA5086 and its material parameters are identified by inverse analysis technique. Then, the proposed constitutive model is verified by comparing numerical and experimental results obtained by tensile tests and Marciniak test, respectively. Finally, the numerical simulation of Marciniak test is carried out at different temperatures (100, 200 and 300 °C) and strain rates (2.5, 120 and 150 s⁻¹), and the effects of temperature and strain rate on the FLCs of AA5086 are investigated and discussed.     

A comparative study on low-velocity impact response of fabric composite laminates

Impact behaviors at low velocity of composite laminates reinforced with fabrics of different architectures are investigated. Unidirectional prepreg, 2D woven and 3D orthogonal fabrics, all formed of Ultrahigh Molecular Weight Polyethylene (UHMWPE) filaments, were selected as reinforcements to form composite laminates using hot pressing technology. Low velocity impact tests were conducted using a drop-weight impact equipment at the energy level of 35 J. A three-coordinate measuring device was employed to determine the volume of plastic deformation and surface dent diameter. The results show that the composite laminates of single-ply 3D orthogonal woven fabric exhibit better energy absorbed capacity and impact damage resistance as compared to those of unidirectional and 2D plain-woven fabric.     

Tension–compression fatigue of a SiC/SiC ceramic matrix composite at 1200 °C in air and in steam

Tension–compression fatigue behavior of a non-oxide ceramic composite with a multilayered matrix was investigated at 1200 °C in laboratory air and in steam. The composite was produced via chemical vapor infiltration (CVI). The composite had an oxidation inhibited matrix, which consisted of alternating layers of silicon carbide and boron carbide and was reinforced with laminated woven Hi-Nicalon™ fibers. Fiber preforms had pyrolytic carbon fiber coating with boron carbide overlay applied. Tension–compression fatigue behavior was studied for fatigue stresses ranging from 80 to 200 MPa at a frequency of 1.0 Hz. Presence of steam significantly degraded the fatigue performance. Specimens that achieved fatigue run-out were subjected to tensile tests to failure to characterize the retained tensile properties. The material retained 100% of its tensile strength. Composite microstructure, as well as damage and failure mechanisms were investigated.     

Thermal and mechanical behaviour of sisal/phenolic composites

This research proposes the development of polymeric composites reinforced with natural fibres to become stronger the damaged timber structures and proposes thermal and mechanical characterization of these composites. Fibres with larger structural applications are glass and carbon fibres but the use of natural fibres is an economical alternative and possesses many advantages such as biodegradability, low cost and is a renewable source. Woven sisal fabric was submitted to heat treatment before moulding and the influence of moisture content of fibres on the composites behaviour was observed. The paper presents mechanical characterization by tensile and flexural strength of woven sisal fabric composites, with and without thermal treatment (at 60 °C for 72 h) on the fabric, thermal characterization by TGA and the manufacturing process by compression moulding. Experimental results show to sisal/phenolic composites a tensile strength and a flexural strength value of 25.0 MPa and 11.0 MPa, respectively, independent to the use of sisal fibres with or without thermal treatment.     

Mechanical properties of woven glass fabric reinforced in situ polymerized poly(butylene terephthalate) composites

Cyclic butylene terephthalate (CBT) has been polymerized in situ at T = 190 °C in the presence and absence of woven glass fabric (WGF). The thermal properties of the in situ polymerized poly(butylene terephthalate) (ISP-PBT) were compared with those of a commercial injection molded PBT (IM-PBT). It was found that the crystallinity of IM-PBT is markedly lower than that of ISP-PBT rendering the latter more brittle. WGF-reinforced (ca. 50 vol.%) ISP-PBT composites were fabricated by compression molding at T = 190 °C using displacement and pressure-controls. Effects of the molding condition were investigated in tensile, three-point bending, short beam shear and dynamic mechanical thermal analysis tests. Both tensile and flexural properties (stiffness and strength), as well as inter-laminar shear strength, were enhanced when the molding occurred under pressure-controlled instead of displacement-controlled conditions. Scanning electron microscopic (SEM) inspection revealed excellent wet-out of the fibers and good interfacial bonding between the fibers and ISP-PBT.     

Artificial neural network and constitutive equations to predict the hot deformation behavior of modified 2.25Cr–1Mo steel

Hot compression tests of modified 2.25Cr–1Mo steel were conducted on a Gleeble-3500 thermo-mechanical simulator at the temperatures ranging from 1173 to 1473 K with the strain rate of 0.01–10 s⁻¹ and the height reduction of 60%. Based on the experimental results, an artificial neural network (ANN) model and constitutive equations were developed to predict the hot deformation behavior of modified 2.25Cr–1Mo steel. A comparative evaluation of the constitutive equations and the ANN model was carried out. It was found that the relative errors based on the ANN model varied from −4.63% to 2.23% and those were in the range from −20.48% to 12.11% by using the constitutive equations, and the average root mean square errors were 0.62 MPa and 7.66 MPa corresponding to the ANN model and constitutive equations, respectively. These results showed that the well-trained ANN model was more accurate and efficient in predicting the hot deformation behavior of modified 2.25Cr–1Mo steel than the constitutive equations.     

Fatigue delamination growth in woven glass/epoxy composite laminates under mixed-mode II/III loading conditions at cryogenic temperatures

We investigate the cryogenic delamination growth behavior in woven glass fiber reinforced polymer (GFRP) composite laminates under mixed-mode II/III fatigue loading. Fatigue delamination tests were conducted with six-point bending plate (6PBP) specimens at room temperature, liquid nitrogen temperature (77 K) and liquid helium temperature (4 K), and the delamination growth rate data for various mixed-mode ratios of Modes II and III were obtained. The energy release rate was evaluated using the three-dimensional finite element method. In addition, the fatigue delamination growth mechanisms were characterized by scanning electron microscopic observations of the specimen fracture surfaces.     

Constitutive analysis to predict high temperature flow stress in 20CrMo continuous casting billet

The experimental true strain–true stress data from isothermal hot compression tests on a Gleeble-1500D thermal simulation machine, across a wide range of temperatures (1173–1373 K) and strain rates (1.5 × 10⁻³–1.5 × 10⁻² s⁻¹), were employed to study the deformation behavior and develop constitutive equations of 20CrMo alloy continuous casting billet steel. The objective was to obtain the relational expression for deformation activation energy and material constants as a function of true strain and the constitutive equation for high temperature deformation of 20CrMo based on the hyperbolic sine form model. A correlation coefficient of 0.988 and an average absolute relative error between the experimental and the calculated flow stress of 8.40% have been obtained. This indicates that the constitutive equations can be used to accurately predict the flow behavior of 20CrMo alloy steel continuous casting billet during high temperature deformation.     

Drop-weight impact of plain-woven hybrid glass–graphite/toughened epoxy composites

The progressive damage behaviors of hybrid woven composite panels (101.6 mm × 101.6 mm) impacted by drop-weights at four different velocities were studied by a combined experimental and 3-D dynamic nonlinear finite element approach. The specimens tested were made of plain-weave hybrid S2 glass-IM7 graphite fibers/toughened epoxy (cured at 177 °C). The composite panels were damaged using a pressure-assisted Instron-Dynatup 8520 instrumented drop-weight impact tester. During these low-velocity simpact tests, the time-histories of impact-induced dynamic strains and impact forces were recorded. The damaged specimens were inspected visually and using ultrasonic C-Scan methods. The commercially available 3-D dynamic nonlinear finite element (FE) software, LS-DYNA, incorporated with a proposed user-defined damage-induced nonlinear orthotropic model, was then used to simulate the experimental results of drop-weight tests. Good agreement between experimental and FE results has been achieved when comparing dynamic force, strain histories and damage patterns from experimental measurements and FE simulations.     

Fabrication and characterization of three-dimensional PMR polyimide composites reinforced with woven basalt fabric

A PMR polyimide composite reinforced with three-dimensional (3D) woven basalt fabric is fabricated for medium high temperature applications. The PMR polyimide matrix resin is derived from 4,4′-methylenediamine (MDA), diethyl ester of 3,3′,4,4′-oxydiphthalic (ODPE) and monoethyl ester of Cis-5-norbornene-endo-2,3-dicarboxylic acid (NE). The rheological properties of the PMR polyimide matrix resin are investigated. Based on the curing reaction of the PMR type polyimide and the rheological properties, an optimum two-step fabrication method is proposed. The three dimensional fabric preforms are impregnated with the polyimide resin in a vacuum oven at 70 °C for 1 h followed by removing the solvent and pre-imidization. The composites are then consolidated by an optimized molding procedure. Scanning electron microscopy analysis shows that needle shaped voids are generated in yarns and the void volume fraction is 4.27%. The decomposition temperature and the temperature at 5% weight loss of the composite post-cured at 320 °C for 24 h are 440 °C and 577 °C, respectively. The dielectric constant and the dielectric loss of the composite are measured by circular cavity method at 7–12 GHz. The tensile strength and the modulus in the warp direction of the composite are 436 MPa and 22.7 GPa. The composite shows a layer-by-layer fracture mode in three-point bending test. The flexure strength and modulus in the warp direction of the composite are 673 MPa and 27.1 GPa, respectively.     

Mechanical behavior and deformation micromechanisms of polypropylene nonwoven fabrics as a function of temperature and strain rate

The mechanical behavior and the deformation and failure micromechanisms of a thermally-bonded polypropylene nonwoven fabric were studied as a function of temperature and strain rate. Mechanical tests were carried out from 248 K (below the glass transition temperature) up to 383 K at strain rates in the range ≈10⁻³ s⁻¹ to 10⁻¹ s⁻¹. In addition, individual fibers extracted from the nonwoven fabric were tested under the same conditions. Micromechanisms of deformation and failure at the fiber level were ascertained by means of mechanical tests within the scanning electron microscope while the strain distribution at the macroscopic level upon loading was determined by means of digital image correlation. It was found that the nonwoven behavior was mainly controlled by the properties of the fibers and of the interfiber bonds. Fiber properties determined the nonlinear behavior before the peak load while the interfiber bonds controlled the localization of damage after the peak load. The influence of these properties on the strength, ductility and energy absorbed during deformation is discussed from the experimental observations.