Design of the hybrid composite journal bearing assembled by interference fit

In this work, a hybrid composite journal bearing (HCJB) composed of carbon/phenolic laminated composite bush and steel housing was designed for marine vessels because the composite journal bearing reduces the possibility of the seizure problem between the journal and bearing. The two components of bearing were assembled by interference fit joining method and a series of durability tests were conducted using the laboratory bench with the lubricants of SAE 30 oil, water, and sea water. That the HCJB was found reliable under the interference fitting loads and environmental temperature change.     

Characteristics of carbon fiber phenolic composite for journal bearing materials

Journal bearing materials are required to have special characteristics such as compatibility with rubbing interface materials, embeddability for particles and wear debris, conformability to accommodate misalignment, thermal and corrosion resistance. Although white metals or babbitt metals used in most journal bearing have almost the required characteristics, they have possibility of seizure between the bearing material and the journal when the oil film is broken.

In this study, a hybrid composite journal bearing composed of carbon fiber reinforced phenolic composite liner and metal backing was manufactured to solve the seizure problem of metallic journal bearing materials because the carbon fiber has self-lubricating ability and the phenolic resin has thermal resistance characteristics. To estimate the wear resistance of carbon fiber phenolic composite, wear tests were performed at several pressures and velocities. The oil absorption characteristics, coefficient of thermal expansion, strength and stiffness of the composite were also tested. Using the measured stiffness values, the thermal residual stresses in the composite were calculated to check the reliability of the composite journal bearing.     

Dynamic compressive response of composite square honeycombs

Carbon fibre-epoxy composite square honeycombs, and the parent composite material, were tested in quasi-static compression at a strain rate of 10⁻³ s⁻¹ and in dynamic compression at strain rates of 10³-10⁴ s⁻¹ using an instrumented Kolsky bar arrangement. Taken together, these tests provide an assessment of the potential of this composite topology for use as a lightweight sandwich core. The honeycombs had two relative densities, 0.12 and 0.24, and two material orientations, ±45° and 0/90° with respect to the prismatic, loading direction of the honeycomb. Honeycomb manufacture was by slotting, assembling and bonding together carbon fibre/epoxy woven plies of composite sheets of 2 × 2 twill weave construction. The peak value of wall stress in the honeycombs was about one third that of the parent material, for all strain rates. An elastic finite element analysis was used to trace the source of this knock-down in strength: a stress concentration exists at the root of the slots and leads to premature failure by microbuckling. Shock-wave effects were evident at impact velocities exceeding 50 ms⁻¹ for the honeycomb of relative density 0.12. This was traced to stubbing of the buckled cell walls against the face of the Kolsky bar.     

Effects of potassium titanate whiskers and carbon fibers on the wear behavior of polyetheretherketone composite under water lubricated condition

The tribological behaviors of polyetheretherketone (PEEK) composite reinforced by carbon fiber (CF) and potassium titanate whiskers (PTW) have been investigated using the pin-on-disk configuration at different applied loads under water lubricated condition. The effects of micrometer carbon fiber and sub-micrometer PTW on the wear properties of the hybrid composite have been discussed. It was found that the PEEK/PTW/CF composite showed excellent tribological performance in water condition. High wear resistance and low friction coefficient were achieved under a wide range of loads. It was revealed that the two fillers worked synergetically to enhance the wear resistance of the hybrid reinforced PEEK composite. The carbon fiber carried the main load between the contact surfaces and protected the matrix from further severe abrasion of the counterpart. At the same time, the exposed PTW out of the polymer matrix around the fiber inhibited the direct scraping between the fiber edge and counterpart tip in some degree, so that the fibers could be less directly impacted during the subsequent sliding process and they were protected from severe damage. In addition, the reinforcement effect of PTW on PEEK could reduce the stress concentration on the carbon fiber-matrix interface, and thereby reduce the CF failure/damage. The reinforcement effect of PTW on PEEK might also restrict the crack initiation and propagation on the surface and subsurface of the composite, and therefore to protect the matrix from fatigue failure during the sliding process.     

Deformation micromechanics of a model cellulose/glass fibre hybrid composite

Interfacial stress transfer in a model hybrid composite has been investigated. An Sm³⁺ doped glass fibre and a high-modulus regenerated cellulose fibre were embedded in close proximity to each other in an epoxy resin matrix dumbbell-shaped model composite. This model composite was then deformed until the glass fibre fragmented. Shifts of the absolute positions of a Raman band from the cellulose fibre, located at 1095 cm⁻¹, and a luminescence band from a doped glass fibre, located at 648 nm, were recorded simultaneously. A calibration of these shifts, for both fibres deformed in air, was used to determine the point-to-point distribution of strain in the fibres around the breaks in the glass fibre. Each break that occurred in the glass fibre during fragmentation was shown to generate a local stress concentration in the cellulose fibre, which was quantified using Raman spectroscopy. Using theoretical model fits to the data it is shown that the interfacial shear stress between both fibres and the resin can be determined. A stress concentration factor (SCF) was also determined for the regenerated cellulose fibre, showing how the presence of debonding reduces this factor. This study offers a new approach for following the micromechanics of the interfaces within hybrid composite materials, in particular where plant fibres are used to replace glass fibres.     

Diametral compression of pultruded composite rods

Diametral compression tests were performed on pultruded composite rods comprised of unidirectional glass or carbon fibers in a common matrix. During compression tests, acoustic emission (AE) activity was recorded and images were acquired from the sample for analysis by digital image correlation (DIC). In both composite systems, localized tensile strain developed in the transverse plane under the load platens prior to failure, producing non-linearity in the load–displacement curve and AE signals. In situ SEM diametral compression tests revealed the development of matrix microcracking and debonding in regions of localized strain, perpendicular to the tensile strain direction (parallel to the load axis). Comparison of linear finite element simulations and experimental results showed a deviation from linear elastic behavior in the load displacement curve. The apparent transverse modulus, in plane shear modulus, and transverse tensile strength of the GF rod was greater than that of the CF rod, and fracture surfaces indicated greater fiber/matrix adhesion in the GF system compared to the CF system. A mixed mode fracture surface showed that two failure modes were active – matrix tensile failure and matrix compression failure by shear near the loading edge.     

Damage sensing of adhesively-bonded hybrid composite/steel joints using carbon nanotubes

Carbon nanotube networks have been used previously for in situ sensing of matrix damage in fiber-reinforced composites. In this research, the ability of carbon nanotube networks to sense and distinguish different types of damage in adhesively-bonded hybrid composite-to-metal joints is evaluated. Toward this end, conductive networks of carbon nanotubes are introduced to the composite substrate as well as the epoxy adhesive. By altering the geometry and chemically treating the steel substrate surface, different failure mechanisms of the single-lap shear joints are achieved. It is demonstrated that these failure mechanisms each possess a distinct resistance response, therefore proving the ability to not only sense failure in situ, but also to distinguish the extent and nature of damage which occurs.     

Large scale hybrid FRP composite girders for use in bridge structures—theory, test and field application

This paper presents the manufacturing process and testing of large scale hybrid composite girders. The evaluation of the girders was a part of the European funded ASSET project. The bridge project, started in 1998 and finished in the autumn of 2002. The ASSET project has in brief covered the design, manufacture and construction of a fully polymer composite traffic bridge. The longitudinal girders are the most important part for the load carrying system of the bridge. Different types of girders were discussed, i.e. steel, concrete or FRP girders. Due to the advantages of FRP girders, for example; light weight, easy installation, superb durability and less maintenance compared to traditional materials it was decided to use FRP in the girders. However, before this could be carried out, tests were needed to verify theoretical calculations. Also a FE-analysis has been carried out, and this analysis is compared with an engineering analytical solution and tests. Both the numerical and the analytical theory correspond quite well with obtained test results.     

System ductility and redundancy of FRP beam structures with ductile adhesive joints

This paper reports on a structural concept for engineering structures composed of FRP components to provide system ductility that compensates for the lack of material ductility inherent to FRP materials. The concept includes the use of redundant structural systems and ductile or flexible adhesive joints. To demonstrate the feasibility of the proposed concept, quasi-static experiments on pultruded GFRP beams were performed. The two-span beams were connected with flexible adhesive joints at the middle support. The flexible joints from highly non-linear adhesives provided a favorable redistribution of the internal and external forces in the statically indeterminate system compared to single-span and continuous beams, which were also examined. In the case of adhesive joint failure, structural collapse was prevented because of system redundancy. Due to the stiffness-governed design of the GFRP beams, the stresses in the flexible adhesive joints were small and creep deformations in the joints could be controlled.     

Design of composite materials with improved impact properties

Composites have been widely used in applications where there is a risk of impact, due to the excellent properties these materials display for absorbing impact energy. However, composites during impact situations typically generate an enormous number of small pieces, due to the energy absorption mechanism of these materials, a mechanism which does not include plastic deformation. This can prove dangerous in sports competitions, where the small fragments of the original structure may harm competitors.This study was designed to explore the possibility of incorporating a material which, whilst maintaining a high level of energy absorption without any plastic deformation mechanism, was able to maintain its original form, or at least significantly reduce the number of pieces generated after impact.The addition of a polyamide layer, NOMEX^®, to a monolithic fabric laminate was investigated in this paper. The process of fabrication is described and the different properties of the material under consideration: interlaminar fracture toughness energy (G_IC), indentation (id) and delamination after impact (A_i) and compression after impact (σ_CAI), were measured and compared with those of the original monolithic fabric.     

Effect of carbon nanotube waviness on the effective thermoelastic properties of a novel continuous fuzzy fiber reinforced composite

This paper deals with the investigation of the effect of carbon nanotube (CNT) waviness on the effective coefficient of thermal expansion (CTE) of a novel continuous fuzzy fiber reinforced composite (FFRC). This novel FFRC is composed of carbon fibers, sinusoidally wavy CNTs and epoxy matrix. The sinusoidally wavy CNTs are radially grown on the circumferential surfaces of the carbon fibers. Analytical micromechanics model based on the method of cells (MOC) approach is derived to investigate the influence of the waviness of CNTs on the effective CTEs of the FFRC. The present study reveals that if the amplitudes of the radially grown sinusoidally wavy CNTs are parallel to the axis of the carbon fiber then the thermoelastic properties of the FFRC are significantly improved over those of the FFRC being composed of straight CNTs.     

Interlaminar and intralaminar reinforcement of composite laminates with aligned carbon nanotubes

Three-dimensional reinforcement of woven advanced polymer–matrix composites using aligned carbon nanotubes (CNTs) is explored experimentally and theoretically. Radially-aligned CNTs grown in situ on the surface of fibers in a woven cloth provide significant three-dimensional reinforcement, as measured by Mode I interlaminar fracture testing and tension-bearing experiments. Aligned CNTs bridge the ply interfaces giving enhancement in both initiation and steady-state toughness, improving the already tough system by 76% in steady state (more than 1.5 kJ/m² increase). CNT pull-out on the crack faces is the observed toughening mechanism, and an analytical model is correlated to the experimental fracture data. In the plane of the laminate, aligned CNTs enhance the tension-bearing response with increases of: 19% in bearing stiffness, 9% in critical strength, and 5% in ultimate strength accompanied by a clear change in failure mode from shear-out failure (matrix dominated) without CNTs to tensile fracture (fiber dominated) with CNTs.     

Effect of filler on thermal aging of composites for next-generation power lines

The thermal aging of pultruded composite rods was investigated to determine the effects of filler on oxidation kinetics and degradation mechanisms. The unidirectional hybrid composite rods were comprised of a carbon-fiber core, a glass-fiber shell, and an epoxy matrix filled with clay particles. A reaction-diffusion model was implemented for each of the two hybrid sections to calculate the oxygen-concentration profile and the thickness of the oxidized layer (TOL) within the composite rods, and results were compared with measured oxidation kinetics. The TOL was measured for samples exposed isothermally in air and in vacuum at 200 °C for up to 13,104 h (1.5 year), and the measured values were similar to modeling predictions (within 10%). The domain validity for the reaction-diffusion model was determined from gravimetric experiments (weight-loss measurement), which showed that after prolonged thermal exposure, the degradation mechanism changed from thermal oxidation to thermal degradation. Thermogravimetric analysis (TGA) was performed to determine the thermal degradation and stability of the aged composite. In addition, the effect of thermal aging on glass transition temperature (T_g) and short beam shear (SBS) strength was determined for isothermal exposures at 180 °C and 200 °C.     

Electrical and thermal property enhancement of fiber-reinforced polymer laminate composites through controlled implementation of multi-walled carbon nanotubes

Aligned carbon nanotubes (CNTs) are implemented into alumina-fiber reinforced laminates, and enhanced mass-specific thermal and electrical conductivities are observed. Electrical conductivity enhancement is useful for electrostatic discharge and sensing applications, and is used here for both electromagnetic interference (EMI) shielding and deicing. CNTs were grown directly on individual fibers in woven cloth plies, and maintained their alignment during the polymer (epoxy) infiltration used to create laminates. Using multiple complementary methods, non-isotropic electrical and thermal conductivities of these hybrid composites were thoroughly characterized as a function of CNT volume/mass fraction. DC and AC electrical conductivity measurements demonstrate high electrical conductivity of >100 S/m (at 3% volume fraction, ∼1.5% weight fraction, of CNTs) that can be used for multifunctional applications such as de-icing and electromagnetic shielding. The thermal conductivity enhancement (∼1 W/m K) suggests that carbon-fiber based laminates can significantly benefit from aligned CNTs. Application of such new nano-engineered, multi-scale, multi-functional CNT composites can be extended to system health monitoring with electrical or thermal resistance change induced by damage, fire-resistant structures among other multifunctional attributes.     

Residual strength distribution of impacted glass/epoxy laminates with embedded shape memory alloy at low temperature

This paper evaluated the strength reduction and probabilistic behaviors of the residual flexural strength for impacted glass/epoxy laminates with embedded shape memory alloy (SMA) wires at various temperatures. A series of impact tests were performed on base (glass/epoxy laminates without SMA wires) and SMA laminates (glass/epoxy laminates with embedded SMA wires) at temperatures of 293 K, 263 K and 233 K. Three point flexural tests were then carried out so as to investigate the post-impact strength at the aforementioned temperatures. Strength reduction behavior of impacted laminates could be described by Caprino’s residual strength prediction model. A probabilistic model was developed in order to estimate the variation in residual strength of the impacted laminates with temperature. As the temperature decreased, the variation in residual strength increased due to the embrittlement of the constituent materials of the laminates at lower temperatures. When compared to the base laminates, the SMA laminates exhibited a higher variation in residual strength, especially at lower temperatures.     

Damage mode characterization of mechanically fastened composite joints using carbon nanotube networks

The practice of upgrading metal parts with composites in large structures has led to an increased use of composite joints, particularly mechanical fastenings, due to ease of assembly and replacement. A drawback of mechanical joints is that damage is difficult to detect visually. In this research, an embedded carbon nanotube network has been used to modify the conductivity of bolted composite joints. In situ electrical resistance measurements in conductive composites have potential to provide quantitative evidence of damage as well as insight into the type of damage which occurs during tensile loading. We demonstrate that the electrical resistance of a bolted composite joint is more sensitive to certain modes of damage (e.g., matrix cracking and delamination) than others (bearing and shear-out), due mostly to the varying amount of void space created, thus proving the potential of an embedded carbon nanotube network in the health monitoring of mechanically fastened cross-ply composites.     

Impact of electrochemical cycling on the tensile properties of carbon fibres for structural lithium-ion composite batteries

Carbon fibres are particularly well suited for use in a multifunctional lightweight design of a structural composite material able to store energy as a lithium-ion battery. The fibres will in this case act as both a high performance structural reinforcement and one of the battery electrodes. However, the electrochemical cycling consists of insertions and extractions of lithium ions in the microstructure of carbon fibres and its impact on the mechanical performance is unknown. This study investigates the changes in the tensile properties of carbon fibres after they have been subjected to a number of electrochemical cycles. Consistent carbon fibre specimens were manufactured with polyacrylonitrile-based carbon fibres. Sized T800H and desized IMS65 were selected for their mechanical properties and electrochemical capacities. At the first lithiation the ultimate tensile strength of the fibres was reduced of about 20% but after the first delithiation some strength was recovered. The losses and recoveries of strength remained unchanged with the number of cycles as long as the cell capacity remained reversible. Losses in the cell capacity after 1000 cycles were measured together with smaller losses in the tensile strength of the lithiated fibres. These results show that electrochemical cycling does not degrade the tensile properties which seem to depend on the amount of lithium ions inserted and extracted. Both fibre grades exhibited the same trends of results. The tensile stiffness was not affected by the cycling. Field emission scanning electron microscope images taken after electrochemical cycling did not show any obvious damage of the outer surface of the fibres.     

The viscoelastic bending stiffness of fiber-reinforced composite Ilizarov C-rings

In order to optimize the design of unidirectional fiber-reinforced composite (Ilizarov) C-rings, the viscoelastic load relaxation behavior was analyzed under a point load. Initially, the deflection and bending stiffness were calculated from the Castigliano theorem and the Euler–Bernoulli bending theory for the elastic solution. The viscoelastic relaxation and creep behavior were then derived from the elastic solution by using the correspondence theorem. Besides the orthotropic mechanical properties of the composite, the asymmetric mechanical properties due to different tensile and compressive properties were also considered. With the exception of the deviation, which was affected by a relatively large thickness ratio to the radius of the C-ring, the calculated relaxation showed good agreement with the experimental result.     

Optimum design of hybrid composite multi-ring flywheel rotor based on displacement method

A structure optimum design based on the displacement method has been performed to maximize the energy storage capacity of a hybrid composite multi-ring flywheel rotor. In the process of optimal design, the preload stress generated by interference assembly, the fiber material failure and the delamination between two adjacent rings under high speed rotation are all considered. Four types of the optimal schemes of energy storage capacity, energy per unit mass (EPM), energy per unit volume (EPV), energy per unit cost (EPC) and energy per unit mass and cost (EPMC) are proposed to satisfy the needs of different applications and optimal designs are carried out by using a sequential quadratic programming (SQP). The optimal results show that all composed rings of the hybrid flywheel rotor can nearly reach the limits of strength in both radial and circumferential directions, and simultaneously the rotor is at the critical state of delamination. The radius parameters and the maximum allowed rotational speed of the hybrid composite flywheel are closely related to the optimal schemes. Considering the effects of angular acceleration and gravity on the delamination will result in the decreasing of energy storage capacities for four typical applications.     

High resolution tomographic imaging and modelling of notch tip damage in a laminated composite

Synchrotron radiation computed tomography (SRCT) has been used to observe in situ damage growth and enable micromechanical damage characterization in [90/0]_S carbon fibre–epoxy composite samples loaded in uniaxial tension to stresses ranging from 30% to 90% of the nominal failure stress. A 3-D finite element model has been constructed to predict crack opening displacements and shear displacements in the 0° plies resulting from thermal residual stress imposed during autoclave cure and from the application of mechanical load. Of particular interest is the demonstration of SRCT as a technique to enable direct, in situ, 3-D, non-destructive damage quantification to assist model development and provide model validation. In addition it has been identified that SRCT has the potential for full field analysis of strain re-distributions during damage growth.