Compressive damage in two-step braided thermoplastic composites

This work examines compression-induced damage in a 3D, braided carbon/nylon 6 composite. The two-step braiding was used to form the fabric, and the yarn used was a carbon tow commingled with nylon 6 powder. About 82% of overall fibers were arranged along the axial direction, and the rest were the braiding fibers. A matched mold was designed for melting the resin and pressing the fabric into a predetermined thickness for the resulting composite. The molding temperature was varied to examine its influence on the compressive properties. The compressive tests were carried out by using an end-supported, end-loaded fixture designed for thicker specimens. The results showed that the molding temperature greatly affected the composite modulus and strength. Microscopic observations revealed that the induced damage modes differ from those in 3D thermosetting composites. Miniscopic failure of the yarns appears to be the dominant mode. Two types of damage were observed. One is miniscopic kink-band caused by the through-thickness shear stress; the other is the folding of the axial yarns into a corrugation form. These modes are related to the 3D structure and the interfacial bonding condition. Some key features of the capability of energy absorption of this material are also discussed.     

Compressive residual thermal stress induced crack deflection in carbon nanotube-doped carbon/carbon composites

Introducing carbon nanotubes (CNTs) by electrophoretic deposition (EPD) is a promising method to improve the strength and toughness of carbon/carbon (C/C) composites. Herein, a new reinforcing mechanism called “compressive residual thermal stress (RTS) induced crack deflection” has been reported. Concretely, CNTs, with different loading content, were introduced by EPD method. Results showed that the CNT content had little influence on CNT-induced matrix refinement. However, the strength of the CNT-doped C/C composites increased with the rising content of CNTs and cracks could only deflect when the CNT interface reached a certain thickness. A theory based on compressive RTS induced crack deflection was built to interpret this discrepancy. Tensile stress existed at the interface in pure C/C composites, while compressive stress occurred and increased with the rising thickness of the CNT interface, which were verified by finite element analysis and Raman test. Calculation revealed that compressive stress exceeded 30 MPa at the crack tip could make the crack deflection happen more easily since it released more strain energy than penetration.     

Fatigue behavior of filament‐wound glass fiber reinforced epoxy composite tubes under tension/torsion biaxial loading

A study of filament‐wound glass fiber/epoxy composite tubes under biaxial fatigue loading is presented. The focus is placed on fatigue lives of tubular specimens under tension/torsion biaxial loading at low cycle up to 100,000 cycles. Filament‐wound glass‐fiber/epoxy tubular specimens with three different lay‐up configurations, namely [±35°]_n, [±55°]_n, and [±70°]_n lay‐ups, are subjected to in‐phase proportional biaxial cyclic loading conditions. The effects of winding angle and biaxiality ratio on the multiaxial fatigue performance of composites are discussed. Specimens are also tested under two cyclic stress ratio: R = 0 and R = −1. The experimental results reveal that both tensile and compressive loading have an influence on the multiaxial fatigue strength, especially for [±35°]_n specimens. A damage model proposed in the literature is applied to predict multiaxial fatigue life of filament‐wound composites and the predictions are compared with the experimental results. It is shown that the model is unsuitable for describing the multiaxial fatigue life under different cyclic stress ratios. POLYM. COMPOS. 28:116–123, 2007. © 2007 Society of Plastics Engineers     

PEDOT‐PSS/singlewall carbon nanotubes composites

Poly(3,4‐ethylenedioxythiophene)‐single wall carbon nanotube (SWNT) composites were prepared via coating methods for improving electrical conductivity and flexibility, minimizing loss of transparency. Three types of surface modified SWNTs were prepared through different modification methods: carboxylated SWNT treated with nitric acid to form carboxylic acid group on their surfaces, 1‐pyrenebutyric acid wrapped SWNT, and 1‐pyrenebutyric acid, lithium salt wrapped SWNT. The surface modifiers had influence on the dispersion states of the SWNTs in 2‐propanol. The dispersion states had influence of aggregate concentrations of surface modified SWNTs in polymer matrix, showing lower aggregate concentration for the carboxylated SWNT than those of the other surface modified SWNTs. The dispersion behaviors of SWNTs were also related with transparency and electrical resistance, and flexibility of composite films. Based on the layer‐by‐layer coating method, SWNT composite film properties such as thickness, transparency, and electrical conductivity could be controlled and would be a good example for improving contradictory properties. POLYM. ENG. SCI., 48:1–10, 2008. © 2007 Society of Plastics Engineers     

In situ observation of damage nucleation in graphite and carbon/carbon composites

The flexure strength and the fracture toughness at 300 K and 77 K were measured in two isotropic polycrystalline graphites with very different microstructure and in one carbon/carbon composite. In addition, the micromechanisms of damage initiation at the notch tip were examined in situ during the fracture tests through a long focal distance microscope. It was found that the mechanical response of carbon-based materials was insensitive to the effect of cryogenic temperatures. In graphite with coarse microstructure, cracks appeared at very low stresses in various points of an ample region surrounding the notch tip, and damage progressed by their stable crack growth and link up. On the contrary, damage was localized at the notch root in graphite with a fine microstructure. High stresses were necessary to nucleate a single crack, which grew unstably, leading to immediate specimen failure. Damage in carbon/carbon composites was nucleated in the form of matrix cracks around the notch tip, but fiber yarns impeded the crack propagation until the load had increased significantly. This process was repeated several times, leading to a serrated load-deflection curve and to a marked increase in the overall fracture resistance.     

The influence of post‐cure on properties of carbon/phenolic resin cured composites and their final carbon/carbon composites

Two‐dimensional (2D) carbon/carbon (C/C) composites were prepared with phenol‐formaldehyde resin and graphite fabric. After curing, polymer composites were post‐cured in air at 160°C and 230°C for several hours and then all polymer composites were carbonized up to 1500°C. The effect of post‐cure on the microstructure and fracture behavior of the resultant carbon/carbon composites was studied. The post‐cure process was characterized by weight loss. This process promoted the crosslinking and condensation reactions and led to the formation of long‐chain, cross‐linked polymeric structures in the matrix. The post‐cured composites had a greater density than the unpost‐cured composite. This study indicates that a longer post‐curing time and higher post‐curing temperature would limit the shrinkage for the post‐cured composites during carbonization. The improvement in linear shrinkage was 22% to 44%. This process also limited the formation of open pores and decreased the weight loss of the resultant C/C composites. The resultant C/C composites developed from post‐cured composites had a greater flexural strength by 7 to 26% over that developed from unpost‐cured composite.     

Preparation and properties of multi‐walled carbon nanotubes/carbon fiber/epoxy composites

Multi‐walled carbon nanotubes/carbon fiber (MWCNTs/CF) hybrid fillers are employed to prepare MWCNTs/CF/epoxy composites. Results reveal that a great improvement of the thermal conductivities of the epoxy composites with the addition of MWCNTs/CF hybrid fillers, and the thermal conductivity of the MWCNTs/CF/epoxy composites is 1.426 W/mK with 8 vol% treated MWCNTs/CF hybrid fillers (5 vol% MWCNTs + 3 vol% CF). Both the flexural and impact strength of the MWCNTs/CF/epoxy composites are increased firstly, but decreased with the excessive addition of MWCNTs. The flexural and impact strength of the MWCNTs/epoxy composites are optimal with 2 vol% MWCNTs. For a given MWCNTs/CF hybrid fillers loading, the surface treatment of MWCNTs/CF hybrid fillers can further increase the thermal conductivities and mechanical properties of the MWCNTs/CF/epoxy composites. POLYM. COMPOS., 35:2150–2153, 2014. © 2014 Society of Plastics Engineers     

Compressive strength and damage mechanisms of 2D-C/SiC composites at high temperatures

Compressive strength of 2D-C/SiC composite was investigated from room temperature(RT) to 1600?°C at present work. Damage evolution was investigated by conducting loading/unloading tests at RT and the damage mechanisms were elucidated by observing the fracture morphology. It is found that compressive strength of 2D-C/SiC was retained until 1200?°C and then decreased with increasing temperature. The variation of compressive strength is closely related to the degradation in matrix modulus. The compressive damage of 2D-C/SiC starts at the buckling of 0° fiber and is followed by opening and closing of original pores, initiation and growth of longitudinal interbundle cracks, separation of 90° fiber bundles by longitudinal cracks, matrix cracking from intrabundle pores, propagation of matrix cracks into 0° fiber bundles, connection of cracks in 0° fiber bundles and longitudinal cracks in 90° fiber bundles.     

Electrical conductivity of vapor‐grown carbon nanofiber/polyester textile‐based composites

Polyamide 6/ethylene–propylene–diene metallocene terpolymer/(ethylene–propylene–diene copolymer)‐graft‐(maleic anhydride) blends with clay (3 and 5 wt % depending on the formulation), different clays (montmorillonite and sepiolite) and different surface functionalization (ammonium salts and silanes) were studied to analyze the effect of the shape of clay and type of modifier on their properties. The results have shown that sepiolite has higher influence on the morphology and on the mechanical properties than montmorillonite. In that sense, blends with 3 wt % of sepiolite have reached the best balanced properties, i.e., tensile modulus and impact strength, than their homologous with montmorillonite. Furthermore, the blends with 3 wt % of sepiolite have reached the highest mechanical properties compared with blends with higher montmorillonite content. © 2012 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013     

Coupled thermal‐electrical analysis of carbon nanotube/epoxy composites

The electrical and thermal behavior of epoxy composites reinforced with different contents of multi‐walled carbon nanotubes (from 0.1 to 0.4 wt% CNT) is studied when they are subjected to relatively high DC voltages (from 1 to 100 V). These materials obey Ohm's law, reaching values of electrical conductivity in the range of 0.01–0.5 S/m. The transported electric current leads to a significant increase of temperature, which is a result of the Joule heating effect. The temperature increases to 40ºC in CNT/epoxy composites when applying 100 V. The study of heating due to Joule's effect gives information about the electrical transport mechanisms implied. It is also confirmed that both, electrical conductivity and Joule's heating effect depend on the morphological features of the composites. The functionalization of CNTs decreases the electrical conductivity of composites but increases their corresponding Joule heating, due to the strong interface between the nanotubes and matrix, which hinders the formation of pathways in CNT in direct contact. The technique of CNT dispersion applied also affects to the increase of temperature induced by the electrical current. POLYM. ENG. SCI., 54:1976–1982, 2014. © 2013 Society of Plastics Engineers     

The effect of carbon nanotubes on the damage development in carbon fiber/epoxy composites

The aim of this study is to investigate the effect of carbon nanotubes (CNTs) on the initiation and development of damage in a woven carbon fiber/epoxy composite under quasi-static tensile loading. The composite is produced using resin transfer moulding and contains 0.25 wt.% of CNTs in the matrix. The results in the fiber direction report no improvement of the Young’s modulus and a slight improvement of the strength and strain-to-failure. The most important result of the study is a notion that CNTs have a hindering effect on the formation of transverse cracks. The conclusion is drawn from a combined analysis of the acoustic emission measurements (reporting a pronounced shift of all damage development thresholds towards higher strains by more than 30%) and X-ray/SEM observations (revealing a lower crack density in the CNT modified composite). The same analysis also indicates that the mechanism of energy dissipation through transverse microcracking is partially replaced by another mechanism that promotes (distributed) damage through fiber debonding.     

Synthesis and characterization of water‐soluble polypyrrole/multi‐walled carbon nanotube composites

Water‐soluble polypyrrole (PPy)/multi‐walled carbon nanotube (MWCNT) composites were prepared by mixing chemically modified MWCNTs carrying carboxylic groups (c‐MWCNTs) and sulfonated PPy (SPPy) aqueous colloids in solution. Fourier transform infrared spectroscopy, Raman spectroscopy, X‐ray photoelectron spectroscopy, X‐ray diffraction, field‐emission scanning electron microscopy and high‐resolution transmission electron microscopy were used to characterize the structure and morphology of the resulting composites. Raman and X‐ray photoelectron spectra demonstrate the presence of electrostatic interactions between the radical species of the SPPy and the carboxylic acid species of the c‐MWCNTs. The addition of c‐MWCNTs into SPPy efficiently enhances its thermal stability and electrical conductivity. Owing to the doping effect and one‐dimensional linear structure of the c‐MWCNTs, the conductivity of SPPy/c‐MWCNT composites at room temperature is increased by two orders of magnitude by the introduction of 5 wt% c‐MWCNTs into the SPPy matrix. Copyright © 2010 Society of Chemical Industry     

Processing‐dependent high impact polystyrene/styrene‐butadiene‐styrene tri‐block copolymer/carbon black antistatic composites

The electrical resistivity and morphology of high impact polystyrene (HIPS)/styrene‐butadiene‐styrene triblock copolymer (SBS)/carbon black (CB) blends were studied. Their antistatic sheets were prepared by both compression‐molding and extrusion calendaring process, with their surface morphology observed using scanning electron microscopy (SEM). The SEM images reveal better dispersion of CB achieved in extrusion‐calendering, resulting in low percolation threshold values in HIPS composites. Higher compression ratio and higher drawing speed (corresponding lower sheet thickness) are beneficial to get better CB dispersion, leading to decreased conductivity for the antistatic sheets. SEM images indicate that strong shear forces in extrusion tend to break the conductive network of CB, resulting in increased surface resistivity. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Ablation resistance of SiC‐modified ZrC coating prepared by SAPS for SiC‐coated carbon/carbon composites

This study evaluated the ablation resistance of ZrC/SiC coating for carbon/carbon (C/C) composites at different temperatures and heat fluxes, which improved the researches on ultra‐high temperature oxidation of ZrC/SiC system. Results showed that the protection of coating depended on temperature and heat flux. Ablation test for 120 seconds under heat flux of 2.4 MW/m² at 2270°C revealed a good ablation resistance, with the linear ablation rate reduced by 96.4% and the mass gain rate increased by 383.3% compared with those of pure ZrC coating. The good ablation resistance was attributed to the formation of dense oxide scale surface. SiC could improve the compactness of the oxide scale at this temperature by forming SiO₂. A dense scale could not form at 2105°C after ablation for 120 seconds, resulting in a dissatisfactory ablation resistance of the coating. After ablation for 120 seconds at 1738°C, the coating was integrated due to the protection of glassy SiO₂ encapsulated ZrO₂. The coating could not resist the strong shear force from the flame at heat flux of 4.2 MW/m² and was severely damaged after ablation for 60 seconds.     

Reinforcement of rigid PVC/wood‐flour composites with multi‐walled carbon nanotubes

Multi‐walled carbon nanotubes (CNT) were compounded with PVC by a melt blending process based on fusion behaviors of PVC. The effects of CNT content on the flexural and tensile properies of the PVC/CNT composites were evaluated in order to optimize the CNT content. The optimized CNT‐reinforced PVC was used as a matrix in the manufacture of wood‐plastic composites. Flexural, electrical, and thermal properties of the PVC/wood‐flour composites were evaluated as a function of matrix type (nonreinforced vs. CNT‐reinforced). The experimental results indicated that rigid PVC/wood‐flour composites with properties similar to those of solid wood can be made by using CNT‐reinforced PVC as a matrix. The CNT‐reinforced PVC did not influence the electrical and thermal conductivity of the PVC/wood‐flour composites. J. VINYL ADDIT. TECHNOL., 2008. © 2008 Society of Plastics Engineers.     

Preparation and properties of nadic‐end‐capped cyclotriphosphazene‐containing polyimide/carbon fiber composites

New novel fire‐resistant and heat‐resistant cyclotriphosphazene‐containing polyimide resins were prepared in situ by the polymerization of (p‐aminophenoxy)(phenoxy)cyclotriphosphazenes with 3,3′,4,4′‐benzophenonetetracarboxylic acid or 3,3′,4,4′‐diphenylsulfonetetracarboxylic acid and a crosslink agent, 5‐norbornene‐2,3‐dicarboxylic acid and were used as polymer matrix compositing with a woven carbon fiber to prepare nadic‐end‐capped cyclotriphosphazene‐containing polyimide/carbon fiber composites. The thermal stability, flame retardance, morphology of the surface fracture, and some physical properties of the composites were investigated by thermogravimetric analysis, scanning electron microscopy, and a material testing system, respectively. The composites had good thermal stability, flame retardance, and mechanical properties. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 90: 810–818, 2003     

Preparation and properties of multiwalled carbon nanotube/epoxy‐amine composites

Different amounts of multiwalled carbon tubes (MWCNTs) were incorporated into an epoxy resin based on diglycidyl ether of bisphenol A and both epoxy precursor and composite were cured with 4,4′‐diamino diphenyl sulfone. Transmission and scanning electron microscopy demonstrated that the carbon nanotubes are dispersed well in the epoxy matrix. Differential scanning calorimetry measurements confirmed the decrease in overall cure by the addition of MWCNTs. A decrease in volume shrinkage of the epoxy matrix caused by the addition of MWCNTs was observed by pressure–volume–temperature measurements. Thermomechanical and dynamic mechanical analysis were performed for the MWCNT/epoxy composites, showing that the T_g was slightly affected, whereas the dimensional stability and stiffness are improved by the addition of MWCNTs. Electrical conductivity measurements of the composite samples showed that an insulator to conductor transition takes place between 0.019 and 0.037 wt % MWCNTs. The addition of MWCNTs induces an increase in both impact strength (18%) and fracture toughness (38%) of the epoxy matrix with very low filler content. © 2012 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013     

Mechanical and thermal transmission properties of carbon nanofiber‐dispersed carbon/phenolic multiscale composites

The present article reports the development and characterization of carbon nanofiber (CNF)‐incorporated carbon/phenolic multiscale composites. Vapor‐grown CNFs were dispersed homogeneously in to phenolic resin using an effective dispersion route, and carbon fabrics were subsequently impregnated with the CNF‐dispersed resin to develop carbon fiber/CNF/phenolic resin multiscale composites. Mechanical and thermal transmission properties of multiscale composites were characterized. Elastic modulus and thermal conductivity of neat carbon/phenolic and multiscale composites were predicted and compared with the experimental results. It was observed that incorporation of only 1.5 wt % CNF resulted in 10% improvement in Young's modulus, 12% increase in tensile strength, and 36% increase in thermal conductivity of carbon/phenolic composites. Fracture surface of composite samples revealed the formation of stronger fiber/matrix interface in case of multiscale composites than neat carbon/phenolic composites. Enhancement of above properties through CNF addition has been explained, and the difference between the predicted values and experimental results has been discussed. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013     

Nanographite-reinforced carbon/carbon composites

Carbon/carbon composites (C/Cs) with nanographite platelets (NGP) filler in a matrix derived from phenolic resin were produced. Different weight concentration (0.5, 1.5, 3, 5 wt.%) NGP were introduced by spraying the NGP during the prepreg formation. The NGP-reinforced C/Cs were characterized for effect of NGP concentration on microstructure, porosity, interlaminar shear strength (ILSS), flexural, ultrasonic and vibration damping behavior. At 1.5 wt.% NGP C/C, the highest values of ILSS observed was 10.5 MPa (increased by 22%), flexure strength of 142.4 MPa (increased by 27%), flexural modulus of 59.2 GPa (increased by 68%) and porosity of 18.8% (reduced by 17.5%) in comparison to neat (without NGP) densified C/C. Ultrasonic testing revealed an average increase of 15% through the thickness Young’s modulus of NGP-C/C; (3.12 GPa at 1.5 wt.% NGP). A 20% average decrease in the damping ratio of the first four modes of vibration was observed in 1.5 wt.% NGP densified C/C. At low concentration (⩽1.5 wt.%) the NGP filled in the pores, cracks and debonded interface but at concentration higher than 1.5 wt.% NGP lost their effectiveness due to agglomeration. The required cycles for desired density/properties are projected to be less compared to neat C/C due to less porosity observed in ⩽1.5 wt.% NGP concentration C/C.