Hot compaction of poly(methyl methacrylate) composites based on fiber shrinkage results

Uniaxial self-reinforced composite poly(methyl methacrylate) (SRC-PMMA) is being investigated as a pre-coat material for the femoral component of total hip replacements. Hot compaction of self-reinforced composites is largely an empirical process which varies the processing parameters of time, temperature and pressure until the desired properties are obtained. Previous work has shown that PMMA fibers have unique thermal relaxation properties dependent upon the retained molecular orientation in them. This work processed composites at times and temperatures that span the relaxation process for a single fiber. It was found that molecular orientation, as measured by birefringence, was lost in composites processed at times greater than relaxation times for single fibers. Flexural properties were also found to vary with processing conditions, with the highest values of 165 ± 15 MPa and 168 ± 3 MPa found at high and low processing times, respectively. These are significantly stronger than unreinforced PMMA which has a flexural strength of 127 ± 14 MPa. It is hypothesized that diffusion between fibers occurs much more quickly than the loss of molecular orientation and it was seen that SRC-PMMA processing conditions can be predicted from the relaxation times and temperatures from single fibers.     

SiCf/SiC复合材料的制备与力学性能

分别采用先驱体裂解-热压和先驱体浸渍-裂解方法制备出了SiCf/SiC复合材料.重点探讨了不同制备工艺对复合材料纤维/基体间界面和断裂行为的影响.研究表明,采用先驱体裂解-热压工艺制备复合材料时,虽然烧结液相可以促进复合材料的致密化,但其同时导致纤维与基体间的界面结合强以及纤维本身性能的退化,因此复合材料表现为脆性断裂,具有较低的力学性能.而采用先驱体浸渍-裂解法制备复合材料时,由于致密化温度较低,复合材料中纤维与基体的界面结合较弱,而且纤维的性能保留率较高,因此,纤维能够较好地发挥补强增韧作用,复合材料具有较好的力学性能,其抗弯强度和断裂韧性分别为703.6MPa和23.1Pa.m1/2.     

Behavior of particle-filled polymer composite under static and dynamic loading

Experimental results of quasi-static and dynamic fracture of particle-filled polymer composite (PFPCM) “ALTUGLAS EI CH25” with a matrix of polymethylmethacrylate (PMMA) are reported in this paper. PMMA matrix is filled with rubber particles, as result a shock-resistant transparent composite is produced. The main task was to investigate experimentally and theoretically the fracture toughness of this composite under static and dynamic loading. A high-rate loading has been created by impulse magnetic field. Analysis of fracture process and its relation with the load parameters and material microstructure have been established. Application of the original testing method enabled determination of fracture toughness at very short loading times and comparison of the results with material dynamic properties. Theoretical analyses are based in general on the notion of delayed fracture. More specifically, the theoretical analysis is based on experimental results and on the hypothesis of fracture incubation time, or delay time.     

Microstructural efficiency and fracture toughness of short fiber/thermoplastic matrix composites

This paper outlines the fracture behavior of composites with thermoplastic matrices of different fracture toughness K_cm (increasing in the order PPS → PET (I) → PET (II) → ETFE → PC). In particular, the way in which the fracture toughness of these composite systems, K_cc, is affected by the volume fraction, orientation and distribution of short glass fibers across the plaque thickness (fiber length ≈ 200 μm, fiber diameter ≈ 10 μm), and by the quality of their interfacial bonding to the matrix is discussed. SEM studies were carried out to define the microstructural details and the dominant mechanisms of energy adsorption during breakdown of the composites.In general, an increase in composite toughness can be expected with increasing extent of reinforcement if the matrix is in a brittle condition (here also verified by K_c-tests at lower temperatures) and if the fibers are well bonded and mostly oriented perpendicular to the crack front. An opposite tendency may occur for matrices which behave in a highly ductile manner even in the presence of fibers. The probability of this behavior is favored in poorly bonded systems. The results are discussed in terms of a ‘microstructural efficiency factor’ M, which mainly considers the relative contributions of fiber and matrix related mechanisms to energy dissipation during breakdown of a composite (‘energy absorption ratio’ n) as well as the reinforcement content and its arrangement in the matrix (‘reinforcing effectiveness parameter’ R).     

Effect of interface modification on PMMA/graphene nanocomposites

Graphene platelets (GnPs) were surface modified with a long-chain surfactant B200, and then compounded with polymethyl methacrylate (PMMA). B200 provided an anchor into GnPs and a bridge into the matrix, thus creating molecular entanglement between matrix and GnPs. The interface modification promoted the dispersion of GnPs, as no aggregates of GnPs were observed on the fracture surface of the modified composites, in sharp contrast with the unmodified composites. Although GnPs formed clusters in the matrix, bilayer graphene was readily observed under TEM in randomly selected regions; it showed high structural integrity under diffraction pattern. The addition of 2.7 vol% m-GnPs produced 32.8 % improvement in the flexural modulus of PMMA as compared to 9.0 % by unmodified GnPs. At 1.1 vol%, the interface-modified composite showed a 19.6 % improvement in the absorption resistance to ethanol, in comparison with 3.8 % for the unmodified composites. The addition of 2.7 vol% m-GnPs improved fracture toughness of PMMA by 79.2 %, while GnPs enhanced it by 23.9 %.     

沥青基炭／炭复合材料的弯曲断裂特征

以1KPAN基高强度炭纤维为增强体、以调制中温煤沥青为基体前躯体,采用压力浸渍－炭化工艺制备出了不同密度二维沥青基炭／炭复合材料。经过对复合材料试样进行的弯曲试验表明,其弯曲断裂特征与材料密度具有密切的联系。根据弯曲强度－位移曲线,高密度复合材料表现为脆性断裂,而低密度复合材料表现为韧性断裂。从弯曲断面的SEM图片来看,脆性断裂时的断面比较平整,韧性断裂时断面上有大量炭纤维拔出。炭／炭复合材料的断裂破坏过程实质上就是基体裂纹在材料内的扩展过程,其扩展的途径与界面结合状况有关。裂纹沿界面的扩展将引起基体与纤维的脱粘,脱粘又导致纤维与基体之间的相对滑动,这种相对滑动将吸收相当一部分能量,从而可以延缓材料的断裂过程,起到韧化作用。     

Fracture toughness and reliability in high-temperature structural ceramics and composites: Prospects and challenges for the 21st century

The importance of high fracture toughness and reliability in Si₃N₄, and SiC-based structural ceramics and ceramic matrix composites is reviewed. The potential of these ceramics and ceramic matrix composites for high temperature applications in defence and aerospace applications such as gas turbine engines, radomes, and other energy conversion hardware have been well recognized. Numerous investigations were pursued to improve fracture toughness and reliability by incorporating various reinforcements such as particulate-, whisker-, and continuous fibre into Si₃N₄ and SiC matrices. All toughening mechanisms, e.g. crack deflection, crack branching, crack bridging, etc essentially redistribute stresses at the crack tip and increase the energy needed to propagate a crack through the composite material, thereby resulting in improved fracture toughness and reliability. Because of flaw insensitivity, continuous fibre reinforced ceramic composite (CFCC) was found to have the highest potential for higher operating temperature and longer service conditions. However, the ceramic fibres should display sufficient high temperature strength and creep resistance at service temperatures above 1000°C. The greatest challenge to date is the development of high quality ceramic fibres with associate coatings able to maintain their high strength in oxidizing environment at high temperature. In the area of processing, critical issues are preparation of optimum matrix precursors, precursor infiltration into fibre array, and matrix densification at a temperature, where grain crystallization and fibre degradation do not occur. A broad scope of effort is required for improved processing and properties with a better understanding of all candidate composite systems.     

Toughening of denture base resin with short deformable fibers

Fracture resistance of polymer reinforced with short fibers consists of a sum of contributions from matrix and fiber fracture, fiber debonding and pull-out. The existing models for predicting dependence of fracture toughness on structural variables were derived for the commercially important fiber volume fractions, i.e., for v_f ? 0.1. In this contribution, modification of the existing model for the dependence of the critical strain energy release rate, G_IC, on the fiber type, length and aspect ratio, interfacial adhesion and volume fraction has been attempted to allow predictions at low v_f < 0.10. The predictions based on the modified model were compared with experimental data on fracture toughness of lightly x-linked PMMA used to manufacture base of removable dentures toughened with short randomly oriented deformable fibers. The composite toughness was measured under impact loading to simulate typical mode of fracture of removable dentures. The G_IC for composites containing short Kevlar 29, S2-glass and poly(vinyl alcohol) (PVOH) fibers were obtained using instrumented Charpy impact tests at room temperature and impact speed of 1.0 m/s. Theoretical prediction based on the proposed model and experimental results agreed reasonably well.     

化学气相浸渗2D Cf/(SiC-C)复合材料的微观结构与强韧性

采用等温等压化学气相浸渗法(ICVI)制备了二维碳纤维增韧碳化硅碳二元基复合材料(2D C_f/(SiC-C)).利用扫描电镜(SEM)和背散射电子成像(BSE)研究了其基体的微观结构, 并与二维碳纤维增韧碳化硅陶瓷基复合材料(2D C_f/SiC)比较了室温力学性能和断口形貌.结果表明：2D C_f/(SiC-C)复合材料的基体是由SiC与热解碳(PyC)组成的多层结构, PyC基体层分布均匀而连续, 且与SiC基体层结合紧密.纤维束内部PyC基体层较厚的2D C_f/(SiC-C)复合材料具有较高的强韧性, 其拉伸强度、断裂应变、断裂韧性和断裂功分别比2D C_f/SiC复合材料的提高了3%、142%、22%和58%.SiC与PyC组成的多层基体使2D C_f/(SiC-C)复合材料的纤维在拔出过程中发生了两次集中拔出, 且第一次集中拔出的纤维对复合材料的强韧性起主要作用.     

Effect of microstructure on elevated-temperature fracture behaviour of two-dimensional carbon/carbon composites

The fracture behaviour of two-dimensional carbon/carbon composites has been studied at temperatures upto 1650°C, using both chevron-and straight-notch single-edge notch beam (SENB) specimens. In all cases, the R-curve behaviour and fracture toughness variations with specimen orientation and temperature are characterized and correlated with the specific microstructure and failure micromechanisms. Higher crack growth resistance and fracture toughness of the longer fibre composite are attributed to the enhanced fibre pull-out and fibre bridging in the following wake region. The relative contribution from the frontal and following wake zone is determined experimentally by the use of renotching methods which demonstrate the effectiveness of the traction zone behind the crack tip. The temperature effects on the toughening mechanisms are examined in terms of crystal structure and fibre matrix interfacial characteristics.     

Fracture toughness and fatigue life of MWCNT/epoxy composites

The present work experimentally characterizes the mode-I fracture toughness and stress–life curve of multi-walled carbon nanotube-(MWCNT-)reinforced epoxy-matrix composites. The effects of carbon nanotube weight fraction and voids on the composite fracture toughness are studied. The average fracture toughness of 1 wt%- and 3 wt%-MWCNT/epoxy composites is 1.29 and 1.62 times of that of pure epoxy, respectively. The 0.5 wt%-MWCNT/epoxy composites’ fatigue lives are 10.5 and 9.3 times of the average fatigue life of neat epoxy, when they are subjected to cyclic loadings with stress amplitudes of 8.67 MPa and 11.56 MPa, respectively. The micrographs indicate that the separation and uniform distribution of MWCNTs in the matrix and the formation of voids significantly affect the fracture and fatigue behavior of MWCNT-reinforced composites.     

Mechanical behavior of SiCf/SiC composites with alternating PyC/SiC multilayer interphases

In order to tailor the fiber–matrix interface of continuous silicon carbide fiber reinforced silicon carbide (SiC_f/SiC) composites for improved fracture toughness, alternating pyrolytic carbon/silicon carbide (PyC/SiC) multilayer coatings were applied to the KD-I SiC fibers using chemical vapor deposition (CVD) method. Three dimensional (3D) KD-I SiC_f/SiC composites reinforced by these coated fibers were fabricated using a precursor infiltration and pyrolysis (PIP) process. The interfacial characteristics were determined by the fiber push-out test and microstructural examination using scanning electron microscopy (SEM). The effect of interface coatings on composite mechanical properties was evaluated by single-edge notched beam (SENB) test and three-point bending test. The results indicate that the PyC/SiC multilayer coatings led to an optimum interfacial bonding between fibers and matrix and greatly improved the fracture toughness of the composites.     

Microstructural characterization and fracture properties of SiC-based fibers annealed at elevated temperatures

Ceramic matrix composites (CMCs) have been proposed as potential structural materials for application of high temperature technologies. Excellent high temperature performance of CMCs requires that fibers must have high enough thermal stability and sufficient mechanical properties throughout the service life. In order to clarify the correlation between the mechanical properties and the microstructure of SiC-based fibers, SiC-based fibers were annealed at elevated temperatures in Ar for 1 h. After annealing, the fracture strengths on these fibers were evaluated at room temperature by tensile test; the microstructural features were characterized by X-ray diffraction (XRD) and field emission scanning electron microscopy (FE-SEM). Furthermore, the fracture mechanics was applied to estimate the fracture toughness and the critical fracture energy of these fibers. As a result, excellent microstructure and mechanical stabilities were observed for SiC fibers with near-stoichiometric composition and high-crystallite structure. Combining the microstructure examination with tensile test indicates that the thermal and mechanical stabilities of SiC fibers at high temperatures were mainly controlled by their crystallization and composition as well as other factors.     

Combined effect of fiber content and microstructure on the fracture toughness of SGF and SCF reinforced polypropylene composites

Composites of polypropylene (PP) reinforced with short glass fibers (SGF) and short carbon fibers (SCF) were prepared with extrusion compounding and injection moulding techniques. The fracture behavior of the two types of composites was studied. The fracture toughness (K _c of the composites was measured in the T-direction [main crack transverse to mould flow direction (MFD)] and in the L-direction (main crack parallel to the MFD) using compact tension (CT) specimens made from the plaques manufactured. The study was focused on the combined effect of fiber volume fraction and microstructure (fiber length and alignment) on the fracture toughness of short fiber composites. It was observed that the addition of fibers effectively enhanced the fracture toughness for both SGF/PP and SCF/PP systems in the T-direction but only improved the composite toughness in the L-direction for the case of a low fiber volume fraction (8%). The composite fracture toughness kept almost unchanged in the T-direction and decreased in the L-direction with increasing fiber volume fraction. These were explained using the combined effect of fiber volume fraction and microstructure.     

Fibre reinforcement and fracture response in geopolymeric mortars

The inorganic polymeric cement called geopolymer or PSS, has been studied in recent years as a binder for mortar and concrete. The present work reports the fracture toughness studies in mortars made of PSS cement matrix reinforced by wollastonite microfibers (Ca(SiO₃)). K_I‐curves for PSS cement composites were determined according to the superposition asymptotic assumption and compared with reference Portland cement (PC) composites. The maximum toughness gain occurs in both composite systems with V_f = 2%. For higher fibre volumes (3 and 5%), K_I values decrease, due to an increase in porosity. Microstructural analyses showed that toughening mechanisms, as debonding and pullout of the fibers, are more common in PSS cement composites than in the reference PC composites. The difference of toughness between PSS and PC cement (0% of fibers) is about 80%. This demonstrates the high performance of these geopolymeric materials.     

Effect of hot water immersion on the performance of carbon reinforced unidirectional poly(ether ether ketone) (PEEK) composites: Stress rupture under end-loaded bending

This paper describes the behaviour of AS4 and T700SC reinforced PEEK composites (SUPreM™ and ACP-2) under applied compressive bending strain. The effect of an increased molecular weight of the polymer matrix on the residual time under endloaded compression bending conditions is studied. Generally for a given composite material, the higher the testing temperature and the applied strain the faster the failure occurs. At test temperatures exceeding the glass transition temperature or at high strain ratios the time-to-failure for CF/PEEK composites follows a master curve. The residual times under endloaded compression bending conditions increase with increasing toughness of the PEEK matrix but decrease with increasing tensile strength of the reinforcing fibres. It seems that the better the fibre/matrix adhesion the lower is the time to failure of an endloaded composite, because more load is transferred from the matrix into the fibres.In order to simulate composite applications under ‘harsh’ conditions the CF/PEEK composites have been exposed to boiling water. PEEK is known to be highly resistant to environmental effects, but water uptake significantly influences the overall performance of CF/PEEK composites under endloaded compression bending conditions. The tensile properties of the composites have been measured as function of exposure time in boiling water. The fibre dominated uniaxial tensile strength is not/or only slightly affected by the boiling water conditioning even after extended exposure times but the transverse tensile strength decreases significantly after exposure to boiling water. The performance of SUPreM™ CF/PEEK-150 and 450 composites under endloaded compression bending conditions are positively affected by water conditioning whereas APC-2 fails at shorter residual times. The fracture behaviour under endloaded conditions is also affected by the ingress of water into the composite.The obtained results show clearly that applications of thermoplastic composites leading to large out of plane deformations can only be ‘safe’ if the maximum service temperatures of the finished part will be well below the glass transition temperature of the polymer matrix otherwise even at low bending radii a dramatic failure of the material cannot be excluded.     

In-situ toughened CFRP composites by shear-calender orientation and fiber-bundle filtration of PA microparticles at prepreg interlayer

Epoxy matrix toughened by polyethersulfone (PES) and polyamide (PA) microparticles was designed and the in-situ interlaminar toughened carbon fiber/epoxy composites were fabricated. Synergistic toughening effect of PES and PA on epoxy matrix was achieved due to semi-IPN structure of PES toughened matrix and uniform dispersion of PA microparticles. Shear-calender orientation of PA microparticles was found during prepreg processing and the microparticles remained on the surface of prepreg due to fiber-bundle filtration. The in-situ formed toughening interlayer of PA microparticles and interfacial bonding between PA and epoxy matrix were detected, which resulted in enhanced fracture toughness, CAI, and transverse flexural strength of the composite based on the PES/PA synergistically toughened matrix. SEM images of fracture morphology of the composite showed evidence of enhanced plastic deformation created by PES and PA, and crack deflection and bridging by PA microparticles.     

Preparation, microstructure and mechanical properties of metal-particulate/glass-matrix composites

Composites with a borosilicate glass matrix containing different concentrations of vanadium particles were fabricated by powder metallurgy and hot-pressing. The mechanical properties and fracture behaviour of the composites were assessed by a range of techniques. Young's modulus, fracture strength in bending, and fracture toughness increased with vanadium content. By virtue of the good interfacial bonding and low residual internal stresses, an effective crack-particle interaction during fracture was achieved. The fracture toughness of composites containing 30 vol. % of vanadium inclusions was approximately 65 % higher than that of the unreinforced glass. Experimental values for the fracture toughness increment were in good qualitative agreement with the predictions of theoretical models in the literature. Extensive plastic deformation of the vanadium inclusions was not found, however. This was attributed mainly to the constraint imposed by the rigid matrix surrounding the particles and to possible embrittlement of the particles during composite fabrication at high temperatures. The brittleness index (B) of the composites was calculated and its relevance for characterisation of the ductile versus brittle behaviour of brittle-matrix composites is discussed.     

Enhancement of fracture toughness of hierarchical carbon fiber composites via improved adhesion between carbon nanotubes and carbon fibers

Hierarchical +1 composites consisting of carbon fibers with carbon nanotubes (CNTs) grown onto them and an epoxy matrix were processed, and the mode I fracture toughness of these composites was evaluated. The mode I fracture toughness of the initial batches of the hierarchical composites was lower than that of the baseline samples without CNTs. Hence, efforts to enhance the adhesion between carbon fibers and CNTs were made, resulting in enhanced adhesion. The enhanced adhesion was confirmed by Scotch tape tests and mode I fracture toughness tests followed by fractographic studies. The mode I fracture toughness of the hierarchical composites with enhanced adhesion was 51% and 89% higher than those of the baseline samples and hierarchical composites with poor adhesion, respectively. Moreover, fractographic studies of the fracture surfaces of the hierarchical composites with enhanced adhesion showed that CNTs were still attached to carbon fibers even after the mechanical tests.     

Influence of processing conditions on bending property of continuous carbon fiber reinforced PEEK composites

The purpose of this study is to achieve an optimum fabrication condition for the continuous carbon fiber reinforced PEEK matrix composites based on a micro-braiding fabrication method. The composite plates were fabricated at three processing temperatures (380, 410 and 440 °C) and three holding times (20, 40 and 60 min), respectively, with a total number of nine different fabrication conditions, and their bending properties were investigated in terms of thermal and fracture characterizations. As a result, the bending performance of the fabricated composites was significantly affected at the 440 °C temperature. Although no significant change in the bending performance was seen at the 380 and 410 °C with all the holding times, the thermal and fracture characterizations implied a degradation of the PEEK matrix property during the fabrication process. In order to avoid the matrix degradation and the decrease of mechanical properties, a lower fabrication temperature with a shorter holding time should be recommended for the carbon/PEEK composites fabricated by the micro-braiding method.