Mechanical, thermal and ablative properties of interply continuous/spun hybrid carbon composites

The mechanical and thermal properties of interply hybrid carbon fiber (continuous and spun fabric)/phenolic composite materials have been studied. Hybrid carbon/phenolic composites (hybrid CP) with continuous carbon fabric of high tensile, flexural strength and spun carbon fabric of better interlaminar shear strength and lower thermal conductivity are investigated in terms of mechanical properties as well as thermal properties.Through hybridization, tensile strength and modulus of spun type carbon fabric reinforced phenolic composites (spun CP) increased by approximately 28% and 20%, respectively. Hybrid CP also exhibits better interlaminar shear strength than continuous carbon fabric/phenolic composites (continuous CP).The in-plane thermal conductivity of hybrid CP is 4-8% lower than that of continuous CP. As continuous filament type carbon fiber volume fraction increases, the transversal thermal conductivity of hybrid CP decreases.The erosion rate and insulation index were examined using torch test. Spun CP has a higher insulation index than continuous CP and hybrid CP over the entire temperature range. Hybrid CP with higher content of spun fabric exhibits higher insulation index as well as lower erosion rate.     

Preparation of multiscale graphene oxide‐carbon fabric and its effect on mechanical properties of hierarchical epoxy resin composite

Graphene oxide (GO) was used to modify the surface of carbon fiber layers through electrophoretic deposition, forming a multiscale reinforcement fabric. By adjusting the experimental parameters, the resulting GO‐carbon fabric showed productive and homogenous distribution of thin and less‐agglomerate GO platelets on carbon fiber surface, remarkably enlarging the surface area and roughness of carbon fabric. To investigate the effect of GO sheets on composites, GO‐carbon fabric and carbon fabric‐reinforced hierarchical epoxy resin composites were respectively manufactured. Mechanical tests demonstrated that after introducing GO flakes on carbon fabric, both the flexural strength and interlaminar shear strength of composite had achieved an increase, especially the interlaminar shear strength rising by 34%. Through fractography analysis, it was found that in pure carbon fabric‐reinforced epoxy composite, the fiber/matrix debonding fracture mechanism predominated, while after the GO decoration on carbon fiber surface, the composite featured a stronger interfacial bonding, leading to the enhancement in mechanical properties of hierarchical epoxy resin composite. POLYM. COMPOS., 37:1515–1522, 2016. © 2014 Society of Plastics Engineers     

Experimental characterization of woven jute‐fabric‐reinforced isothalic polyester composites

In this article, mechanical performance of isothalic polyester‐based untreated woven jute‐fabric composites subjected to various types of loading has been experimentally investigated. The laminates were prepared by hand lay‐up technique in a mold. Specimens for tests were fabricated as per ASTM standards. All the tests (except impact) were conducted on closed loop servo hydraulic MTS 810 material test system using data acquisition software Test Works‐II. From the results obtained, it was found that the tensile strength and tensile modulus of jute‐fabric composite are 83.96% and 118.97% greater than the tensile strength and modulus of unreinforced resin, respectively. The results of other properties, such as flexural, in‐plane shear, interlaminar shear, impact, etc., also revealed that the isothalic‐polyester‐based jute‐fabric composite have good mechanical properties and can be a potential material for use in medium load‐bearing applications. The failure mechanism and fiber‐matrix adhesion were analyzed by scanning electron microscope. Effects of long‐term immersion in water on mechanical properties are also presented. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 104: 2650–2662, 2007     

Hybrid effect on mechanical properties of M40‐T300 carbon fiber reinforced Bisphenol A Dicyanate ester composites

Interply and intraply hybrid composites based on Bisphenol A Dicyanate ester (BADCy), high strength carbon fibers T300, and high modulus carbon fibers M40 were prepared by monofilament dip‐winding and press molding technique. The tensile, flexural, interlaminar shear properties and SEM analysis of the hybrid composites with different fiber content and fiber arrangement were investigated. The results indicated that the mechanical properties of intraply hybrid composites were mainly determined by fiber volume contents. When the ratio of fiber volume content was close to 1:1, the intraply hybrid composites possessed lowest tensile and flexural strength. The mechanical properties of interply hybrid composite mainly depended on the fiber arrangement, instead of the fiber volume contents. The hybrid composites using T300 fiber layout as outside layer possessed high flexural strength and low flexural modulus, which was close to that of T300/BADCy composites. The hybrid composites ([(M40)_x/(T300)_y]_S) using M40 fiber layout as outside layer and T300 fibers in the mid‐plane had high flexural modulus and interlaminar shear strength. POLYM. COMPOS., 2010. © 2010 Society of Plastics Engineers     

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     

The effect of pyrolysis on the properties of stabilized PAN fabric reinforced phenolic resins for 2D carbon/carbon composites

Two-dimensional (2D) carbon/carbon composites were prepared with phenol-formaldehyde resin and a commercial stabilized PAN fabric. The effect of pyrolysis on the microstructure and flexural strength of the composites during the carbonization process was studied. The interaction between fabric and matrix inhibited the decomposition and the thermal fragmentation, leading to a higher carbon yield for the final composition. Because of the formation of strong bonding in the fiber/matrix interface, the composites made with stabilized PAN fabric showed catastrophic failure and low flexural strength below carbonization temperatures of 600°C. Above 600°C, the flexural strength of the composites increased with the increase in the carbonization temperatures, even when the fracture behavior showed catastrophic failure.     

Effects of graphite filler loading and heat treatment temperature on the properties of phenolic resin based carbon–carbon composites

Carbon/carbon composites (C/Cs) were prepared through polymer pyrolysis using PAN based carbon fabric (Panex^(R) 35) and resol type phenolic resin having 0, 10, 20, 30, and 40 wt% of graphite fillers. These precursor composites were heat treated at 600, 900, and 1200°C. The effects of filler loading on the precursor composites and their C/Cs were investigated through density, microstructure, and mechanical properties. Since, the precursor composites were prepared under similar processing conditions and technique, at any particular filler loading when the heat treatment temperature increases, the bulk density of the samples decreases. The filler addition accelerates the formation of the carbon basal planes in the matrix supported by X‐ray diffraction studies. The properties such as tensile strength and strain decrease continuously mainly due to change in the matrix structure and decrease of density, whereas, the interlaminar shear strength (ILSS) and interlaminar fracture toughness (ILFT) increase mainly because of improvement in the modulus of matrix. At any particular heat treatment temperature, depending on the filler content and matrix type, the density, tensile properties, ILSS, and ILFT of the samples show different trends. POLYM. COMPOS., 2011. © 2011 Society of Plastics Engineers     

Carbon/carbon composites derived from poly(ethylene oxide)‐modified novolac‐type phenolic resin: Microstructure and physical,and morphological properties

A poly(ethylene oxide) (PEO) novolac‐type phenolic resin blend was prepared by the physical blending method. The modified novolac‐type phenolic resin with various PEO contents was used as a matrix precursor to fabricate carbon/carbon composites. The effect of the PEO/phenolic resin mixing ratio on the change of the density and of the porosity was studied. The flexural strength and interlaminar shear strength of the PEO/phenolic resin blend‐derived carbon/carbon composites were also investigated. The results show that the density of the PEO/phenolic resin blend‐derived carbon/carbon composites decreases with the PEO content. The X‐ray diffraction and Raman spectra studies showed that the carbon fiber in the samples will affect the growth of the ordered carbon structure. From SEM morphological observation, it is shown that the fracture surface of specimens is smooth. Also, there is less fiber pull‐out and fiber breakage on the fracture surface. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 84: 1609–1619, 2002; DOI 10.1002/app.10407     

Experimental characterization of traditional composites manufactured by vacuum‐assisted resin‐transfer molding

The primary purpose of this study is to investigate the anisotropic behavior of different glass‐fabric‐reinforced polyester composites. Two commonly used types of traditional glass fabrics, woven roving fabric and chopped strand mat, have been used. Composite laminates have been manufactured by the vacuum infusion of polyester resin into the fabrics. The effects of geometric variables on the composite structural integrity and strength are illustrated. Hence, tensile and three‐point‐bending flexural tests have been conducted at different off‐axial angles (0, 45, and 90°) with respect to the longitudinal direction. In this study, an important practical problem with fibrous composites, the interlaminar shear strength as measured in short‐beam shear tests, is discussed. The most significant result deduced from this investigation is the strong correlation between the changes in the interlaminar shear strength values and fiber orientation angle in the case of woven fabric laminates. Extensive photographs of fractured tensile specimens resulting from a variety of uniaxial loading conditions are presented. Another aim of this work is to investigate the interaction between the glass fiber and polyester matrix. The experiments, in conjunction with scanning electron photomicrographs of fractured surfaces of composites, are interpreted in an attempt to explain the interaction between the glass fiber and polyester. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Hybrid multi‐scale epoxy composites containing conventional glass microfibers and electrospun glass nanofibers with improved mechanical properties

A mechanically flexible mat consisting of structurally amorphous SiO₂ (glass) nanofibers was first prepared by electrospinning followed by pyrolysis under optimized conditions and procedures. Thereafter, two types of hybrid multi‐scale epoxy composites were fabricated via the technique of vacuum assisted resin transfer molding. For the first type of composites, six layers of conventional glass microfiber (GF) fabrics were infused with the epoxy resin containing shortened electrospun glass nanofibers (S‐EGNFs). For the second type of composites, five layers of electrospun glass nanofiber mats (EGNF‐mats) were sandwiched between six layers of conventional GF fabrics followed by the infusion of neat epoxy resin. For comparison, the (conventional) epoxy composites with six layers of GF fabrics alone were also fabricated as the control sample. Incorporation of EGNFs (i.e., S‐EGNFs and EGNF‐mats) into GF/epoxy composites led to significant improvements in mechanical properties, while the EGNF‐mats outperformed S‐EGNFs in the reinforcement of resin‐rich interlaminar regions. The composites reinforced with EGNF‐mats exhibited the highest mechanical properties overall; specifically, the impact absorption energy, interlaminar shear strength, flexural strength, flexural modulus, and work of fracture were (1097.3 ± 48.5) J/m, (42.2 ± 1.4) MPa, (387.1 ± 9.9) MPa, (12.9 ± 1.3) GPa, and (30.6 ± 1.8) kJ/m², corresponding to increases of 34.6%, 104.8%, 65.4%, 33.0%, and 56.1% compared to the control sample. This study suggests that EGNFs (particularly flexible EGNF‐mats) would be an innovative type of nanoscale reinforcement for the development of high‐performance structural composites. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 42731.     

Thermomechanical properties of alkali treated jute‐polyester/nanoclay biocomposites fabricated by VARTM process

A systematic study was carried out to investigate the effect of alkali treatment and nanoclay on thermomechanical properties of jute fabric reinforced polyester composites (JPC) fabricated by the vacuum‐assisted resin transfer molding (VARTM) process. Using mechanical mixing and sonication process, 1% and 2% by weight montmorillonite K10 nanoclay were dispersed into B‐440 premium polyester resin to fabricate jute fabric reinforced polyester nanocomposites. The average fiber volume was determined to be around 40% and void fraction was reduced due to the surface treatment as well as nanoclay infusion in these biocomposites. Dynamic mechanical analysis (DMA) revealed enhancement of dynamic elastic/plastic responses and glass transition temperature (T_g) in treated jute polyester composites (TJPC) and nanoclay infused TJPC compared with those of untreated jute polyester composites (UTJPC). Alkali treatment and nanoclay infusion also resulted in enhancement of mechanical properties of JPC. The maximum flexural, compression, and interlaminar shear strength (ILSS) properties were found in the 1 wt % nanoclay infused TJPC. Fourier transform‐infrared spectroscopy (FT‐IR) revealed strong interaction between the organoclay and polyester that resulted in enhanced thermomechanical properties in the composites. Lower water absorption was also observed due to surface treatment and nanoclay infusion in the TJPC. © 2012 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013     

Mechanical properties of glass fabric/polyester composites: Effect of silicone coatings on the fabrics

An experimental investigation was carried out to study the effect of a silicone coating on the mechanical properties of polyester/woven glass fabric composites, fabricated by resin transfer molding. E‐glass woven fabrics were coated with a silicone elastomer by solution dip coating. The effect of variation of silicone amounts on the impact resistance, toughness, and mechanical properties of the composite was determined. Short beam shear tests were performed to assess the effect of coating on the adhesion of the fiber to the matrix. The coated specimens exhibited worse interlaminar shear strength over that of uncoated fabrics. Three‐point bending tests were also performed to investigate the effect of the coating on flexural properties. Whereas flexural strength and Young's modulus decreased with increasing amount of coating, the toughness, represented by the area under the stress–strain curve, presented a maximum. Finally, notched Izod impact tests were carried out and the curve for the energy absorbed during impact versus the amount of coating also appeared to have a maximum, indicating an interesting slot for optimum impact performance. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 91: 1300–1308, 2004     

Influence of adding Mesocarbon Microbeads into C/C composites on microstructure and properties during carbonization

This work tests the effect on microstructure, flexural strength, flexural moduli, plus the electrical and thermal conductivity of carbon/carbon composites with Mesocarbon Microbeads (MCMBs) content ranging 0–30% by weight during carbonization. These composites were reinforced by oxidative PAN Base fiber felts, and matrix precursor was resol‐type‐phenolic resin. MCMBs with a weight fraction of 0–30% were added to the matrix to elucidate the effect. Liquid‐phase impregnation was applied to reinforce matrix carbon. Cured composites were stabilized at 230°C, then heat‐treated at 400, 600, 800, 900 and 1000°C for carbonization. The measured flexural strength after heat‐treated at 1000°C was 51.20, 49.59, 43.55, and 38.76 MPa for MCMBs with 0, 10, 20, and 30% added to composites; mean flexural moduli were l.73, 1.24, 0.73, and 0.57 MPa, respectively. Adding MCMBs reduced both strength and modulus because of cracks and avoids caused by different shrinkage between resin and MCMBs; adding 30 wt % MCMBs raised thermal conductivity of C/C composites from 1.55 to 1.78 W/mK and reduced electric resistivity from 1.8 × 10^?2 to 5.97 × 10^?3 Ω cm. effect. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 102: 3102–3110, 2006     

Fabrication of hybrid matrix/silane modified carbon fabric composites and study of their mechanical properties

Carbon fiber reinforced polymer composites are an extremely strong and light fiber-reinforced plastics that contains carbon fiber. In the present study, carbon fabrics were treated with various weight percentages of silane and were confirmed by spectral analysis (Fourier transform infrared). The treated carbon fibers were reinforced in hybrid resin (a combination of vinyl ester and epoxy at a ratio of 80:20) by using vacuum-assisted resin transfer mold technique. The composites were tested to know their tensile strength, modulus, flexural strength, modulus, and interlaminar shear strength. The hybrid matrix specimen was also prepared and tested for the mechanical properties and confirmed the miscibility by differential scanning calorimetry and X-ray diffraction. The mechanical properties of hybrid matrix composites (HMCs) were studied by fracture surface morphology with scanning electron microscope. The mechanical properties of the HMCs increased with silane treatment. © 2019 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2019 , 136, 47695.     

Effect of deposited carbon nanotubes on interlaminar properties of carbon fiber‐reinforced epoxy composites using a developed spraying processing

Carbon fiber‐reinforced epoxy composites, with incorporated carboxylic multiwall carbon nanotubes (CNTs), were prepared using vacuum‐assisted resin infusion (VARI) molding, and the in‐plane and out‐of‐plane properties, including mode‐I (G_Ic) and mode‐II (G_IIc) interlaminar fracture toughness, interlaminar shear strength (ILSS), tensile, and flexural properties were measured. A novel spraying technique, which sprays a kind of epoxy resin E20 with high viscosity after spraying the CNTs, was adopted to deposit the CNTs on the surface of carbon fiber fabric. The E20 was used to anchor CNTs on the fabric surface, avoiding that the deposited CNTs were removed by the infusing resin during VARI process. The spraying processing, including spraying amount and spraying sequence, was optimized based on the distribution of CNTs on the fibers. After that, three composite specimen groups were fabricated using different carbon fiber fabrics, including as‐received, CNT‐deposited with E20, and CNT‐deposited without E20. The effects of CNTs on the processing quality and mechanical properties of carbon fiber‐reinforced polymer composites were studied. The experimental results show that all studied laminates have uniform thickness with designed values and no obvious defects form inside the laminates. Compared with the composite without CNTs, depositing CNTs with E20 increases by 24% in the average propagation G_Ic, by 11% in the propagation G_IIc and by 12% in the ILSS, while it preserves the in‐plane mechanical properties, However, depositing CNTs without E20 reduces interlaminar fracture toughness. These phenomena are attributed to the differences in the distribution of CNTs and the fiber/matrix interfacial bonding for different spraying processing. POLYM. COMPOS., 2013. © 2012 Society of Plastics Engineers     

Comparison of mechanical properties of epoxy composites reinforced with stitched glass and carbon fabrics: Characterization of mechanical anisotropy in composites and investigation on the interaction between fiber and epoxy matrix

The primary purpose of the study is to evaluate and compare the mechanical properties of epoxy‐based composites having different fiber reinforcements. Glass and carbon fiber composite laminates were manufactured by vacuum infusion of epoxy resin into two commonly used noncrimp stitched fabric (NCF) types: unidirectional and biaxial fabrics. The effects of geometric variables on composite structural integrity and strength were illustrated. Hence, tensile and three‐point bending flexural tests were conducted up to failure on specimens strengthened with different layouts of fibrous plies in NCF. In this article, an important practical problem in fibrous composites, interlaminar shear strength as measured in short beam shear test, is discussed. The fabric composites were tested in three directions: at 0°, 45°, and 90°. In addition to the extensive efforts in elucidating the variation in the mechanical properties of noncrimp glass and carbon fabric reinforced laminates, the work presented here focuses, also, on the type of interactions that are established between fiber and epoxy matrix. The experiments, in conjunction with scanning electron photomicrographs of fractured surfaces of composites, were interpreted in an attempt to explain the failure mechanisms in the composite laminates broken in tension. POLYM. COMPOS., 2008. © 2008 Society of Plastics Engineers     

Effect of carbon fabric type on the mechanical performance of 2D carbon/carbon composites

A stabilized PAN fabric was carbonized and graphitized from 800°C to 2500°C. Two-dimensional (2D) carbon/carbon composites were made using the stabilized PAN fabric, carbonized fabrics, and a resol-type phenol-formaldehyde resin. These composites were heat-treated from 600°C to 2500°C. The influence of different heat-treated fabrics and heat treatment on the fracture and flexural strength of these composites was also studied. The composite reinforced with higher heat-treated fabrics showed a lower weight loss than that with lower heat-treated fabrics. When the composites were graphitized at 2500°C, the loss was 49.7 wt% for the composite made with stabilized PAN fabric and 26 wt% for that with carbonized fabric at 2500°C. Those composites also have a higher density than composites produced by other methods. Composites made with stabilized PAN fabric exhibited a strong bonding in the fiber/matrix during pyrolysis. This composite showed catastrophic fracture and a smooth fracture surface with no fiber pullout. Composites made with higher carbonized fabrics exhibited a weak interface bonding. These composites showed a pseudo-plastic fracture pattern with fiber pullout during pyrolysis. Composites made with carbonized fabrics at 2000°C and 2500°C showed the highest flexural strength at the prolysis temperature of 1000°C. Composites made with carbonized fabric at 1300°C showed the highest flexural strength above 1500°C to 2500°C. The composite made with stabilized PAN fabric exhibited the lowest flexural strength during pyrolysis.     

Nanoparticle dispersed resins and composites under quasi‐static loading: Shear plugging behavior

Experimental studies are presented on the quasi‐static shear plugging behavior of nanoparticle dispersed materials viz symmetric balanced cross‐ply laminates made using unidirectional E‐glass fabric with epoxy resin, and neat epoxy resin. The nanoparticles used are nanosilica and multiwalled carbon nanotube for E‐glass/epoxy and nanosilica for epoxy resin. The effect of nanoparticle dispersion on shear plugging strength was evaluated. Shear plugging strength was enhanced up to 10.5% for E‐glass/epoxy and up to 17.0% for neat epoxy resin on addition of nanoparticles. Shear plugging strength of nanoparticle dispersed composites decreased with an increase in specimen thickness. POLYM. COMPOS., 37:3411–3415, 2016. © 2015 Society of Plastics Engineers     

Effect of carbon fiber surface functional groups on the mechanical properties of carbon-carbon composites with HTT

The present investigation describes the quantitative measurement of surface functional groups present on commercially available different PAN based carbon fibers, their effect on the development of interface with resol-type phenol formaldehyde resin matrix and its effect on the physico-mechanical properties of carbon-carbon composites at various stages of heat treatment. An ESCA study of the carbon fibers has revealed that high strength (ST-3) carbon fibers possess almost 10% reactive functional groups as compared to 5.5 and 4.5% in case of intermediate modulus (IM-500) and high modulus (HM-45) carbon fibers, respectively. As a result, ST-3 carbon fibers are in a position to make strong interactions with phenolic resin matrix and HM-45 carbon fibers make weak interactions, while IM-500 carbon fibers make intermediate interactions. This observation is also confirmed from the pyrolysis data (volume shrinkage) of the composites. Bulk density and kerosene density more or less increase in all the composites with heat treatment up to 2600 °C. It is further observed that bulk density is minimum and kerosene density is maximum upon heat treatment at 2600 °C in case of ST-3 based composites compared to HM-45 and IM-500 composites. It has been found for the first time that the deflection temperature (temperature at which the properties of the material start to decrease or increase) of flexural strength as well as interlaminar shear strength is different for the three composites (A, B and C) and is determined by the severity of interactions established at the polymer stage. Above this temperature, flexural strength and interlaminar shear strength increase in all the composites up to 2600 °C. The maximum value of flexural strength at 2600 °C is obtained for HM-45 composites and that of ILSS for ST-3 composites.     

Enhancement of interlaminar fracture toughness of carbon fiber–epoxy composites using polyamide‐6,6 electrospun nanofibers

In this study, carbon fiber–epoxy composites are interleaved with electrospun polyamide‐6,6 (PA 66) nanofibers to improve their Mode‐I fracture toughness. These nanofibers are directly deposited onto carbon fabrics before composite manufacturing via vacuum infusion. Three‐point bending, tensile, compression, interlaminar shear strength, Charpy impact, and double cantilever beam tests are performed on the reference and PA 66 interleaved specimens to evaluate the effects of PA 66 nanofibers on the mechanical properties of composites. To investigate the effect of nanofiber areal weight density (AWD), nanointerlayers with various AWD are prepared by changing the electrospinning duration. It is found that the electrospun PA 66 nanofibers are very effective in improving Mode‐I toughness and impact resistance, compressive strength, flexural modulus, and strength of the composites. However, these nanofibers cause a decrease in the tensile strength of the composites. The glass‐transition temperature of the composites is not affected by the addition of PA 66 nanofibers. © 2017 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2017 , 134, 45244.