Effect of coupling agents on reinforcing potential of recycled carbon fibre for polypropylene composite

Polypropylene (PP) composites reinforced with recycled carbon fibre have been prepared through extrusion compounding and injection moulding. The reinforcing potential of the recycled fibre was increased by improving the interfacial adhesion between the fibre and PP matrix and this was done by the addition of maleic anhydride grafted polypropylene (MAPP) coupling agents. Three MAPP couplers with different molecular weights and maleic anhydride contents were considered. The effects on the mechanical properties of the composite were studied, and scanning electron microscopy (SEM) was used to study the fracture morphology of the tensile specimens. It was observed that with the addition of MAPP the interfacial adhesion was improved as fewer fibres were pulled-out and less debonding was seen. A microbond test was performed and a significant improvement in interfacial shear strength was measured. This resulted in composites with higher tensile and flexural strengths. The maximum strength was achieved from MAPP with the highest molecular weight. Increased modulus was also achieved with certain grades of MAPP. It was also found that the composite impact strength was improved significantly by MAPP, due to a higher compatibility between the fibre and matrix, which reduced crack initiation and propagation.     

Pull-through performance of carbon fibre epoxy composites

An investigation of the through-thickness properties of carbon fibre prepreg laminates, Non-Crimp Fabric laminates and non-crimp 3D orthogonal woven composites by pull-through testing was performed. Influence of matrix system and curing temperature on the performance of the 3D woven composites was investigated.     

Commingled natural fibre/polypropylene wrap spun yarns for structured thermoplastic composites

A major challenge for natural fibre composites is to achieve high mechanical performance at a competitive price. Composites constructed from yarns perform better than composites made from random nonwoven mats. However, the twist structure of conventional ring spun yarns prevents the full utilization of fibre mechanical properties in the final composites. We produced flax/polypropylene commingled wrap yarns in which all flax fibres were twistless. Composites made from the wrap yarn demonstrated significant improvement of flexural modulus. Most currently available low cost natural fibres, such as decorticated hemp, cannot be efficiently made into yarns because of their lack of cohesion. Adding polypropylene fibres to decorticated hemp improved textile processing performance. The polypropylene fibres served as a carrier for the natural fibres during processing and became the polymer matrix in the final composites.     

Controlled growth of CuO nanowires on woven carbon fibers and effects on the mechanical properties of woven carbon fiber/polyester composites

The effect of CuO nanowires on the improvement of the mechanical properties of woven carbon fiber (WCF)-based polyester resin composite was studied. The composite was manufactured by the vacuum-assisted resin transfer molding (VARTM) process. CuO nanowires were grown on woven carbon fiber sheets in subsequent steps of seeding followed by growth. Scanning electron microscopy (SEM) showed the growth of CuO nanowires on the surface of the carbon fibers; this growth increased with the number of seeding cycles and the length of the growth time. The concentration of the growth solution did not have a significant effect. The maximum amount of growth occurred for 8 seeding cycles with a 60 mM growth solution and a growth time of 8 h. An analysis of the percent weight change, along with X-ray diffraction (XRD) and Fourier transform infrared (FTIR) spectroscopy, supported the above findings. The crystalline peak height of the CuO nanowires increased with the nanowire growth. The new absorption peaks arising in the FTIR spectra also indicated growth of CuO nanowires on the WCF. The mechanical properties in terms of tensile strength, modulus, and impact resistance improved significantly after the growth of nanowires on the carbon fibers: the modulus and strength improved by up to 33.1% and 42.8%, while the impact energy absorption increased by 136.8% relative to bare WCF.     

Additive manufacturing of carbon fiber reinforced thermoplastic composites using fused deposition modeling

Additive manufacturing (AM) technologies have been successfully applied in various applications. Fused deposition modeling (FDM), one of the most popular AM techniques, is the most widely used method for fabricating thermoplastic parts those are mainly used as rapid prototypes for functional testing with advantages of low cost, minimal wastage, and ease of material change. Due to the intrinsically limited mechanical properties of pure thermoplastic materials, there is a critical need to improve mechanical properties for FDM-fabricated pure thermoplastic parts. One of the possible methods is adding reinforced materials (such as carbon fibers) into plastic materials to form thermoplastic matrix carbon fiber reinforced plastic (CFRP) composites those could be directly used in the actual application areas, such as aerospace, automotive, and wind energy. This paper is going to present FDM of thermoplastic matrix CFRP composites and test if adding carbon fiber (different content and length) can improve the mechanical properties of FDM-fabricated parts. The CFRP feedstock filaments were fabricated from plastic pellets and carbon fiber powders for FDM process. After FDM fabrication, effects on the tensile properties (including tensile strength, Young's modulus, toughness, yield strength, and ductility) and flexural properties (including flexural stress, flexural modulus, flexural toughness, and flexural yield strength) of specimens were experimentally investigated. In order to explore the parts fracture reasons during tensile and flexural tests, fracture interface of CFRP composite specimens after tensile testing and flexural testing was observed and analyzed using SEM micrograph.     

Epoxy composites containing CFRP powder wastes

The increasing utilisation of carbon materials increases the waste generation. Therefore, it is necessary to analyse recycling alternatives. In this research, carbon powder wastes obtained from the cutting process of laminate composites have been incorporated into epoxy matrix phase in order to improve the mechanical characteristics. Physical and mechanical properties, hardness, abrasion, erosion and thermal behaviour have been analysed. Results show that carbon powder wastes incorporated to new epoxy matrix phases act basically as reinforcement. This allows for the recycling of the residues as well as improves some properties of the composites.     

Complementary percolation characteristics of carbon fillers based electrically percolative thermoplastic elastomer composites

Electrically percolative composites of thermoplastic elastomers (TPE) filled with different concentrations of carbon nanotubes (CNT), carbon black (CB) and (CNT–CB) hybrid fillers were fabricated by melt blending. The effects of filler type and composition on the electrical properties of the percolative TPE composites were studied. Percolation threshold for CB-, CNT- and (CNT–CB)-based composites was found to be 0.06, 0.07 and 0.07 volume fraction respectively. Compared to CB-based composites and earlier reported results, CNT- and (CNT–CB)-based ones revealed an unexpectedly high percolation threshold, which otherwise considered an unwelcome phenomenon, lead to distinct and rare percolation characteristics of CNT filled percolative composites like per-percolation conductivity and a relatively steep percolation curves. CB-based composites showed a comparatively sharp insulator–conductor transition curve complementing the percolation characteristics CNT- and (CNT–CB)-based composites. Percolation threshold conductivity of the fillers was in the order of CB > CNT > (CNT–CB), while maximum attained conductivities followed the order of CNT > (CNT–CB) > CB. Conductivity order of fillers not only denied much reported synergic effect in (CNT–CB) filler but also highlighted the effect of percolation characteristics on the outcome of conductivity values. Results obtained were of theoretical as well as practical importance and were explained in the context of filler morphology and different dispersion characteristics of the carbon based fillers.     

Fabrication and mechanical properties of carbon short fiber reinforced barium aluminosilicate glass–ceramic matrix composites

Dense BaSi₂Al₂O₈ (BAS) and Ba_0.75Sr_0.25Si₂Al₂O₈ (BSAS) glass–ceramic matrix composites reinforced with carbon short fibers (C_sf) were fabricated by hot pressing technique. The microstructure, mechanical properties and fracture behavior of the composites were investigated by X-ray diffraction, scanning and transmission electron microscopies, and three-point bend tests. The carbon fibers had a good chemical compatibility with the glass–ceramic matrices and can effectively reinforce the BAS (or BSAS) glass–ceramic because of associated toughening mechanisms such as crack deflection, fiber bridging and pullout effects. Doping of BAS with 25 mol% SrSi₂Al₂O₈ (SAS) can accelerate the hexacelsian to celsian transformation and result in the formation of pure monoclinic celsian in C_sf/BSAS composites, which can avoid the undesirable reversible hexacelsian to orthorhombic transformation at 300 °C and reduce the thermal expansion mismatch between the fiber and matrix.     

Vibration damping characteristics of carbon fiber-reinforced composites containing multi-walled carbon nanotubes

Vibration damping characteristic of nanocomposites and carbon fiber reinforced polymer composites (CFRPs) containing multiwall carbon nanotubes (CNTs) have been studied using the free and forced vibration tests. Several vibration parameters are varied to characterize the damping behavior in different amplitudes, natural frequencies and vibration modes. The damping ratio of the hybrid composites is enhanced with the addition of CNTs, which is attributed to sliding at the CNT-matrix interfaces. The damping ratio is dependent on the amplitude as a result of the random orientation of CNTs in the epoxy matrix. The natural frequency shows negligible influence on the damping properties. The forced vibration test indicates that the damping ratios of the CFRP composites increase with increasing CNT content in both the 1st and 2nd vibration modes. The CNT-epoxy nanocomposites also show similar increasing trends of damping ratio with CNT content, indicating the enhanced damping property of CFRPs arising mainly from the improved damping property of the modified matrix. The dynamic mechanical analysis further confirms that the CNTs have a strong influence on the composites damping properties. Both the dynamic loss modulus and loss factor of the nanocomposites and the corresponding CFRPs show consistent increases with the addition of CNTs, an indication of enhanced damping performance.     

Functionalization of multi-wall carbon nanotubes with silane and its reinforcement on polypropylene composites

Multi-wall carbon nanotubes (MWCNTs) were functionalized with a silane coupling agent. The MWCNTs were first coated with inorganic silica by a sol–gel process and then grafted with 3-methacryloxypropyltrimethoxysilane (3-MPTS). The grafting of 3-MPTS onto the MWCNTs surface was confirmed by Fourier-transform infrared spectroscopy, transmission electron microscopy and X-ray photoelectron spectra. Polypropylene (PP) composites filled with raw MWCNTs and functionalized MWCNTs were prepared and characterized. The PP/3-MPTS functionalized MWCNTs composite has higher tensile strength than the PP/raw MWCNTs composite. This is explained by the organic groups of 3-MPTS grafted onto the surface of MWCNTs.     

Evaluating the mechanical properties of reinforced LDPE composites made with carbon fibres recovered via solvothermal processing

Carbon fibre was recovered from a thermoset composite via a solvo-thermal process and used as reinforcement in low density polyethylene (LDPE). The oxidized recovered carbon fibres have shown better properties than original non-oxidized fibres. The best interactions between the continuous and dispersed phases were found using 3-aminopropyl-trimetoxysilane and experimentally synthesized polyalkenyl-polymaleic anhydride based polymers. The tensile strength of the prepared composites nearly doubled when 3-aminopropyl-trimetoxysilane was used as compatibilizer, in comparison to the composites prepared without additives. Based on infrared analysis, a chemical reaction has been proposed between –COOH groups of compatibilizers and the –OH groups of the carbon fibre surface for the best composites.     

Influence of titanium carbide on the interlaminar shear strength of carbon fibre laminate composites

The potential use of carbon fibre laminate composites is limited by the weak out-of-plane properties, especially delamination resistance. The effect of incorporating titanium carbide to the mesophase pitch matrix precursor of carbon fibre laminate composites on interlaminar shear strength is studied both on carbonised and graphitised composites. The presence of titanium carbide modifies the optical texture of the matrix from domains to mosaics in those parts with higher concentrations and it contributes to an increase of fibre/matrix bonding. This fact produces an increase of the interlaminar shear strength of the material and changes the fracture mode.     

Compressive failure of hybrid multidirectional fibre-reinforced composites

In this paper, the hybridisation of multidirectional carbon fibre-reinforced composites as a means of improving the compressive performance is studied. The aim is to thoroughly investigate how hybridisation influences the laminate behaviour under different compression conditions and thus provide an explanation of the “hybrid effect”. The chosen approach was to compare the compressive performance of two monolithic carbon fibre/epoxy systems, CYTEC HTS/MTM44-1 and IMS/MTM44-1, with that of their respective hybrids. This was done by keeping the same layup throughout ((0/90/45/−45)_2S) while replacing the angle plies in one case or the orthogonal plies in the other case with the second material, thus producing two hybrid systems. To investigate the compressive performance of these configurations, compact and plain compression test methods were employed which also allowed studying the sensitivity of compressive failure to specimen geometry and loading conditions. The experimental results and the subsequent fractographic analysis revealed that the hybridisation of selective ply interfaces influenced the location and severity of the failure mechanisms. Finally, in light of this knowledge, an update of the generic sequence of events, previously suggested by the authors, which lead to global fracture in multidirectional fibre-reinforced composites under compression is presented.     

Fatigue life evaluation for carbon/epoxy laminate composites under constant and variable block loading

This paper presents the results of current research on the fatigue life prediction of carbon/epoxy laminate composites involving twelve balanced woven bidirectional layers of carbon fibres and epoxy resin manufactured by a vacuum moulding method. The plates were produced with 3 mm thickness and 0.66 fibre weight fraction. The dog bone shape specimens were cut from these plates with the load line aligned with one of the fibre directions. The fatigue tests were performed using load control with a frequency of 10 Hz and at room temperature. The fatigue behaviour was studied for different stress ratios and for variable amplitude block loadings. The damage process was monitored in terms of the stiffness loss. The fatigue life of specimens submitted to block loading tests was modelled using Palmgren–Miner’s law and taking in to account the stress ratio effect. The estimated and experimental fatigue lives were compared and good agreement was observed.     

Novel bio-commingled composites based on jute/polypropylene yarns: Effect of chemical treatments on the mechanical properties

This paper mainly investigates the fabrication process of jute yarn reinforced, bidirectional thermoplastic commingled composites (both untreated and treated). Commingling method was used to prepare the composites wherein the Polypropylene yarn (PP yarn) and jute yarn were wound together onto a metal plate in a particular configuration and then compression moulded. The mechanical properties of the composites prepared from chemically treated jute yarn were found to increase substantially compared to those of untreated ones. The surface morphologies of the fracture surfaces of the composites were recorded using scanning electron microscope (SEM). The SEM micrographs reveal that interfacial bonding between the treated jute yarn and the matrix has improved significantly by chemical treatments. The various chemical treatment mechanisms have been supported by FT-IR spectra. Theoretical modelling was used to predict the tensile properties and was found to be in accordance with the experimental results.     

Growth of carbon nanotubes on carbon fibre substrates to produce hybrid/phenolic composites with improved mechanical properties

Carbon nanotubes were grown by chemical vapor deposition (CVD) on different carbon fibre substrates namely, unidirectional (UD) carbon fibre tows, bi-directional (2D) carbon fibre cloth and three dimensional (3D) carbon fibre felt. These substrates were used as the reinforcement in phenolic resin matrix to develop hybrid CF–CNT composites. The growth morphology and other characteristics of the as grown tubes were analyzed by scanning electron microscopy (SEM), transmission electron microscopy (TEM) and thermal gravimetry (TGA) which confirmed a copious growth of multiwalled carbon nanotubes (MWNTs) on these substrates. The mechanical properties of the hybrid composites was found to increase with the increasing amount of deposited carbon nanotubes. The flexural strength (FS) improved by 20% for UD, 75% for 2D and 66% for 3D hybrid composites as compared to that prepared by neat reinforcements (without CNT growth) under identical conditions. Flexural modulus (FM) of these composites also improved by 28%, 54% and 46%, respectively.     

Properties of composites of carbon nanotube fibres

Composites have set the standard for high strength materials for several decades. With the discovery of nanotubes, new possibilities for reinforced composites have arisen, with potential mechanical properties superior to those of currently available materials. This paper reports the properties of epoxy matrix reinforced with fibres of carbon nanotubes (CNTs) which, in many ways, are similar to standard composites reinforced with commercial fibres. The composites were formed by the back diffusion of the uncured epoxy into an array of aligned fibres of CNTs. The fibre density and volume fraction were measured from thermogravimetric analysis (TGA). Properties in tension and compression were measured, and the level of fibre–matrix interaction analysed fractographically. The results show the significant potential for this route to CNT reinforcement.     

Extraction and preparation of bamboo fibre-reinforced composites

Natural plant fibre composites have been developed for the production of a variety of industrial products, with benefits including biodegradability and environmental protection. Bamboo fibre materials have attracted broad attention as reinforcement polymer composites due to their environmental sustainability, mechanical properties, and recyclability, and they can be compared with glass fibres. This review classifies and describes the various procedures that have been developed to extract fibres from raw bamboo culm. There are three main types of procedures: mechanical, chemical and combined mechanical and chemical extraction. Composite preparation from extracted bamboo fibres and various thermal analysis methods are also classified and analysed. Many parameters affect the mechanical properties and composite characteristics of bamboo fibres and bamboo composites, including fibre extraction methods, fibre length, fibre size, resin application, temperature, moisture content and composite preparation techniques. Mechanical extraction methods are more eco-friendly than chemical methods, and steam explosion and chemical methods significantly affect the microstructure of bamboo fibres. The development of bamboo fibre-reinforced composites and interfacial adhesion fabrication techniques must consider the type of matrix, the microstructure of bamboo and fibre extraction methods.     

Morphology and electrical properties of polyamide 6/polypropylene/multi-walled carbon nanotubes composites

Morphology, electrical properties and conductive mechanisms of polyamide 6/polypropylene/muti-walled carbon nanotubes (PA6/PP/MWNTs) composites with varied compositions and different blending sequences were investigated. The MWNTs were found to be located preferentially in the PA6 phase in the composites, whatever the PA6 was continuous or dispersed phase. While the incorporation of MWNTs changed the dispersed PA6 phase from spherical to elongated or irregular shape. The PA6/PP/MWNTs (20/80/4) composite with a dispersed PA6 phase exhibited a higher electrical conductivity in comparison with the PA6/PP/MWNTs (50/50/4) composite which has a co-continuous phase and exhibits double percolation. This was due to the formation of a conductive MWNTs networks in the PA6/PP/MWNTs (20/80/4) composite as proved by means of field emission scanning electron microscopy and rheological measurements. The morphology and electrical properties of the PA6/PP/MWNTs (20/80/4) composites were significantly influenced by blending sequences. When blending 3.9 phr MWNTs with a pre-mixed PA6/PP/MWNTs (20/80/0.1) composite, the dispersed PA6 phase formed an elongated structure, which was beneficial to the electrical properties.     

Mechanical performance of carbon fibre-reinforced composites based on stitched and bindered preforms

The cost-reduced manufacturing of complex textile preforms suitable for liquid composite moulding of high-performance fibre-reinforced polymer composites is of significant importance for today’s aerospace industry. In this study, stitching technologies combined with thermally induced preform stabilisation by incorporation of thermoplastic binder-materials are demonstrated to be one of the key approaches towards achieving this challenging goal. However, the potential reduction of the in-plane mechanical composite properties induced by stitching and/or added binders may outweigh the cost savings and the anticipated improvements of the out-of-plane performance. In order to obtain excellent overall mechanical composite properties, innovative low-melting temperature or soluble thermoplastic stitching yarns as well as their corresponding binder non-woven mats were utilised to prepare novel preforms for non-crimped carbon fibre-reinforced epoxy composites; effectively allowing an enhanced stabilisation of the dry performs by thermobonding. These promising results emphasize the feasibility and the benefits of adopting advanced stitching technologies for high-performance composites.