Investigation of the long term effects of moisture on carbon fibre and epoxy matrix composites

The aim of this work is to investigate the long term effects of moisture on the interface between a carbon fibre and an epoxy matrix. High modulus carbon fibres were used to prepare single fibre model composites based on an epoxy resin. The samples were immersed in the seawater and demineralised water and their moisture uptake behaviour was monitored. The equilibrium moisture content and diffusion coefficients for the samples were determined. DSC has been used to analyse the moisture effects on glass transition temperature and thermal stability of the pure epoxy specimens. These results showed a reduction in the glass transition temperature (T_g) after moisture absorption. Tensile tests were also carried out for the epoxy specimens and a general decrease in the mechanical properties of the epoxy matrix was observed. Raman spectroscopy was used to observe the effects of moisture on the axial strain of the carbon fibre within the composite and stress transfer at the interface as a function of exposure time. The results show that the decrease in the mechanical and interfacial properties of the model composites under the seawater immersion is more significant than under demineralised water immersion.     

Tailoring of dual-interface in high tenacity PP composites – Toughening with positive hybrid effect

The study proves the feasibility of manufacturing injection moulded polypropylene composites reinforced with short rayon cellulose fibres of two selectively tailored fibre–matrix interfaces. The originally developed method relies on selective chemical grafting of two different polymer waxes onto the surface of cellulose fibres in order to obtain two different strengths of fibre–matrix interfaces in one composite. This selective tailoring of a dual-interface is meant to improve the notched impact strength without deteriorating of its flexural strength. Compatibilised fibres have a strong interphase, which conditions the transfer of strain from the matrix to fibres during deformation. Fibres tailored for a weak interface more efficiently hinder the crack propagation at crash. A 32% improvement of composite notched impact strength was achieved with merely a 5% deterioration of its flexural strength. Its specific properties are on the level or better than those of polypropylene counterpart reinforced with the same content of glass fibres.     

The influence of hydrothermal conditioning on the Mode-I,thermal and flexural properties of Carbon/Benzoxazine composites with a thermoplastic toughening interlayer

Carbon/Benzoxazine laminates with and without non-woven thermoplastic fibrous polyamide (PA) veils at the interlaminar regions were manufactured using Vacuum Assisted Resin Transfer Moulding (VARTM). The effect of the interlaminar thermoplastic veils on the Mode-I strain energy release rate (G_IC), flexural stiffness, glass transition temperature (T_g) and water absorption behaviour was determined using two commercially available Benzoxazine resins. Despite an increase in the maximum moisture content, the veils greatly enhanced G_IC by an increase in fibre bridging of PA fibres, with concurrent reductions in flexural stiffness. Water ingress resulted in large reductions in the T_g, although no significant change was observed due to the PA interlayers. Fibre bridging and fibre pull-out were the main mechanisms by which the veils assisted in resisting delamination. The presence of the water was observed to degrade mechanical properties due to a reduction in fibre/matrix interfacial strength, molecular degradation and plasticisation of the matrix.     

Characterisation of interfaces in Al–Zn–Mg alloy reinforced with Sicabo fibres

Abstract

The microstructure of a metal matrix composite consisting of an Al–Zn–Mg alloy reinforced with SiC coated boron fibres has been examined by electron microscopy, electron probe microanalysis, and by optical microscopy. Considerable amounts of Mg₂Si phase were found to be segregated at the fibre/matrix interface. This intermetallic was not formed by a reaction between the fibre and matrix during the fabrication process, a liquid infiltration technique, but as a result of silicon impurities present as contaminants in the melt. It was concluded that the interface phase was precipitated from the metal matrix in the later stages of solidification without any nucleation role being played by the fibre. The Mg₂Si phase appears to be brittle and was present in amounts likely to have a deleterious effect on the strength of the composite.

MST/871     

Agrofibre reinforced poly(lactic acid) composites: Effect of moisture on degradation and mechanical properties

Natural fibre reinforced PLA composites are a 100% biobased material with a promising mechanical properties profile. However, natural fibres are hygroscopic whereas PLA is sensitive to hydrolytic degradation under melt processing conditions in the presence of small amounts of water. Here, we determine the effect of water content in undried and dried natural fibres on semi crystalline grade PLA degradation during processing as well as on the composite’s mechanical performance. The fibres evaluated are ramie, flax and cotton, containing 6–9 mass% moisture in the undried state and 0.2–0.4 mass% in the dried state. Intrinsic viscosity and melt flow index analysis indicate that the effect of the different levels of moisture in the fibres have a similar and small effect on PLA degradation, PLA hydrolysis appears rather affected by fibre diameter. Morphology, flexural strength and stiffness and Charpy impact of the composites are not significantly affected by the water present in the undried fibres.     

Moisture absorption of unidirectional hybrid composites

Unidirectional hybrid composite rods were conditioned in humid air to investigate the sorption kinetics and the effects of moisture on mechanical and physical properties. Sorption curves were obtained for both hybrid and non-hybrid composite rods to determine characteristic parameters, including the diffusion coefficient (D) and the maximum moisture uptake (M_∞). The moisture uptake for the hybrid composites generally exhibited Fickian behavior (no hybridization effects), behaving much like non-hybrid composites. A two-dimensional diffusion model was employed to calculate moisture diffusivities in the longitudinal direction. Interfaces and thermally-induced residual stresses affected the moisture diffusion. In addition, the effect of hygrothermal aging on glass transition temperature (T_g), short beam shear strength (SBS), and tensile strength was determined for hygrothermal exposure at 60 °C and 85% relative humidity (RH). Property retention and reversibility of property degradation were also measured. Microscopic inspection revealed no evidence of damage.     

Continuous fibre composites with a nanocomposite matrix: Improvement of flexural and compressive strength at elevated temperatures

Polymer layered silicate nanocomposites can improve the flexural and compressive strength of continuous fibre reinforced composites by means of increasing the matrix modulus. A three-phase thermoplastic composite consisting of a main reinforcing phase of woven glass fibres and a polyamide 6 (PA6) nanocomposite matrix was fabricated. Flexural testing of a conventional PA6 fibre composite has shown a decrease of the flexural strength upon increasing temperature. This behaviour is associated with the decrease of the matrix modulus, especially above T_g. The nanocomposite used in this study has a modulus that is much higher than unfilled PA6, even above T_g and after moisture conditioning. The results showed that the fibre composites with a nanocomposite matrix have a more than 40% increased flexural and compressive strength at elevated temperatures. This also means that the temperature at which the materials can be used is increased by 40–50 °C. Therefore, by using a nanocomposite matrix the high temperature performance of fibre composites can be improved without any change in processing conditions. The combination with other advantages of nanocomposites in areas such as barrier properties, flammability and creep makes this a very attractive approach.     

Flax fibre and its composites – A review

In recent years, the use of flax fibres as reinforcement in composites has gained popularity due to an increasing requirement for developing sustainable materials. Flax fibres are cost-effective and offer specific mechanical properties comparable to those of glass fibres. Composites made of flax fibres with thermoplastic, thermoset, and biodegradable matrices have exhibited good mechanical properties. This review presents a summary of recent developments of flax fibre and its composites. Firstly, the fibre structure, mechanical properties, cost, the effect of various parameters (i.e. relative humidity, various physical/chemical treatments, gauge length, fibre diameter, fibre location in a stem, oleaginous, mechanical defects such as kink bands) on tensile properties of flax fibre have been reviewed. Secondly, the effect of fibre configuration (i.e. in forms of fabric, mat, yarn, roving and monofilament), manufacturing processes, fibre volume, and fibre/matrix interface parameters on the mechanical properties of flax fibre reinforced composites have been reviewed. Next, the studies of life cycle assessment and durability investigation of flax fibre reinforced composites have been reviewed.     

Mechanical properties of 3D KD-I SiCf/SiC composites with engineered fibre-matrix interfaces

Three-dimensional (3D) silicon carbide (SiC) matrix composites reinforced with KD-I SiC fibres were fabricated by precursor impregnation and pyrolysis (PIP) process. The fibre-matrix interfaces were tailored by pre-coating the as-received KD-I SiC fibres with PyC layers of different thicknesses or a layer of SiC. Interfacial characteristics and their effects on the composite mechanical properties were evaluated. The results indicate that the composite reinforced with as-received fibre possessed an interfacial shear strength of 72.1 MPa while the composite reinforced with SiC layer coated fibres had a much higher interfacial shear strength of 135.2 MPa. However, both composites showed inferior flexural strength and fracture toughness. With optimised PyC coating thickness, the interface coating led to much improved mechanical properties, i.e. a flexural strength of 420.6 MPa was achieved when the interlayer thickness is 0.1 μm, and a fracture toughness of 23.1 MPa m^1/2 was obtained for the interlayer thickness of 0.53 μm. In addition, the composites prepared by the PIP process exhibited superior mechanical properties over the composites prepared by the chemical vapour infiltration and vapour silicon infiltration (CVI-VSI) process.     

Tensile properties of real unidirectional Kevlar/epoxy composites

Mechanical behaviour, tensile strength and failure modes in real unidirectional Kevlar/epoxy composites, loaded parallel to the fibres, at volume fraction (V_f) range 0.26–0.73, were investigated. It was found that the measured tensile strengths deviated from the expected values calculated from the Rule of Mixture. The deviation, which was minimal at V_f of about 0.5, was mainly due to geometrical deficiencies typical of real composites. At V_f<0.5 it could be explained by non-homogeneous fibre spread and distribution of fibres. At V_f>0.5 the deviation was explained by the increasing lack of matrix between some adjacent fibres and by squeezing of fibres. The initial part of loading was typified by straightening out of non-axial fibres, accompanied by fibre/matrix debonding. The straightening process was completed at a stress level of about 0.6–0.7 of the composite strength. Matrix damage began at this stress level and continued to develop up to final failure. Failure of Kevlar fibres was noted to occur only at an extremely short loading interval coinciding with the catastrophic final failure. This was due to the small scatter of Kevlar fibre strength.     

Strain-sensitive Raman spectroscopy and electrical resistance of carbon nanotube-coated glass fibre sensors

This paper presents the development of glass fibres coated with nanocomposites consisting of carbon nanotubes (CNTs) and epoxy. Single glass fibres with different CNT content coating are embedded in a polymer matrix as a strain sensor for composite structures. Raman spectroscopy and electrical response of glass fibres under mechanical load are coupled for in situ sensing of deformation in composites. The results show that the fibres with nanocomposite coating exhibit efficient stress transfer across the fibre/matrix interface, and these with a higher CNT content are more prone to fibre fragmentation at the same matrix strain. A relationship between the fibre stress and the change in electrical resistance against the fibre strain is established. The major finding of this study has a practical implication in that the fibres with nanocomposite coating can serve as a sensor to monitor the deformation and damage process in composites.     

Water absorption study on pultruded jute fibre reinforced unsaturated polyester composites

Water absorption of natural fibre plastic composites is a serious concern especially for their potential outdoor applications. In this research, jute fibre reinforced with unsaturated polyester composites are subjected to water immersion tests in order to study the effects of water absorption in its mechanical properties. Water absorption tests were conducted by immersing composite specimens into three different environmental conditions included distilled water, sea water and acidic solutions at room temperature for a period up to 3 weeks. Water absorption curves obtained and characteristic parameter D (diffusion coefficient) and M_m (maximum moisture content) were determined. The water absorption of jute fibre reinforced unsaturated polyester composites were found to follow a so-called pseudo-Fickian behaviour. The effects of the immersion treatment on the flexural and compression characteristics were investigated. The flexural and compression properties were found to decrease with the increase in percentage water uptake. These flexural and compression behaviours were explained by the plasticization of the matrix–fibre interface and swelling of the jute fibres.     

Influence of interfacial stress transfer on fatigue crack growth in SiC-fibre reinforced titanium alloys

An important damage mechanism during fatigue of unidirectional SiC-fibre reinforced titanium alloys is the formation of matrix cracks transverse to the fibre direction. Due to the relatively low fibre/matrix bond strength these matrix cracks initially do not break the fibres, so that matrix cracks bridged by fibres develop. It is shown experimentally, that the strong drop in fatigue strength is caused by the formation of a bridged crack of a critical size and the crack propagation rate (da/dN) for a single load level has been determined. A prediction of da/dN on the basis of finite element calculation of the stress intensity factor range of the bridged matrix crack ΔK_m and the ΔK_m–da/dN relationship of the used titanium alloy (Timetal 834) has been performed. Calculation of ΔK_m assuming a negligible fibre/matrix bond strength and considering shear load transfer at the fibre/matrix interface due to Coulomb friction (coefficient of friction μ=0.5 and μ=0.9) led to a large discrepancy between the measured and predicted crack growth rate. It can be concluded, that the assumed conditions of stress transfer at the fibre/matrix interface neglecting bonding is the reason for this discrepancy.     

Studies on carbon fibre reinforced aluminium composite processed using pre-treated carbon fibres

Carbon fibre reinforced Al-12% Si alloy composite has been fabricated by pre-treating the fibres with K₂ZrF₆ followed by molten alloy infiltration and subsequent hot pressing of the preforms. The infiltration conditions were arrived at based on the measurement of tensile strength of the fibres extracted from the preforms. The fibre volume per cent of 20 was found to result in composite tensile strength of about 240 MPa as compared to tensile strength of 100 MPa for the unreinforced matrix. Characterization of the interface revealed the formation of ZrSi₂ and diffusion of potassium and aluminium into the fibre. The interfacial bonding was strong as is evinced by the absence of fibre pull-out on to the fracture surface.     

ESEM investigations for assessment of damage kinetics of short glass fibre reinforced thermoplastics - Results of in situ tensile tests coupled with acoustic emission analysis

The damage mechanisms of short glass fibre reinforced polypropylene (PP) and polybutene-1 (PB-1) materials were investigated. For this purpose, in situ tensile tests were conducted in the environmental scanning electron microscope (ESEM) while simultaneously recording the acoustic emission (AE). To be able to observe damage mechanisms directly during loading, notched specimens were used. This method allows the direct correlation of the recorded load - elongation data with observed damage mechanisms, as well as correlations with acoustic emission data. Hence, it is possible to describe the damage kinetics of short glass fibre composite.It was found that different bonding conditions of the two investigated materials result in different damage mechanisms as well as in different AE behaviour. For fibre reinforced PP with excellent bonding conditions of the fibres in the polymeric matrix, fibre fracture, slipping of fibres in the delamination area, debonding and pull-out with matrix yielding was observed. The determined AE parameter amplitude A_p and energy E_AE for the PB-1 material are lower because of the weak bonding of the fibres to the PB-1-matrix. Hence, energy dissipative damage mechanisms like pull-out with matrix yielding can occur only in a limited part of such materials.     

Effects of fibre volume fraction on the stress transfer in fibre pull-out tests

The elastic stress transfer taking place across the fibre/matrix interface is analysed for the fibre pull-out test by means of both micromechanics and finite element (FE) analyses. A special focus has been placed on how fibre volume fraction, V_f, affects the interface shear stress fields in the model composites containing both single and multiple fibres. In a so-called ‘three-cylinder model’, where a fibre, a matrix and a composite medium are coaxially located, the constraint imposed on the central fibre due to the surrounding fibres is properly evaluated. It is shown in the FE analysis that the differences in stress distributions between the composite models containing single and multiple fibres become increasingly prominent with increasing V_f. The principal effect of the presence of surrounding fibres in the multiple-fibre composite model is to suppress effectively the development of stress concentration near the embedded fibre end and thus eliminate the possibility of debond initiation from this region for all V_f considered. This is in sharp contrast to the single-fibre composite model, in which the interfacial debond can propagate from the embedded end if V_f is larger than a critical value. These findings are essentially consistent with the results from micromechanics analysis on the same specimen geometry. The implications of the results for the practical fibre pull-out test as a means of measuring the interface properties are discussed.     

Gaining knowledge on the processability of PLA-based short-fibre compounds – A comprehensive comparison with their PP counterparts

The present study provides a quantitative overview of bio-based compound processing compared to commonly used composites reinforced with short glass fibres (GF). Three reinforcing fibres were compounded with polylactide and polypropylene: abaca, man-made cellulose and conventional E-GF. The flow behaviour of corresponding melts was determined using melt flow rate (MFR) and online flow spiral test. The composite structures were analysed by means of SEM in order to investigate the fibre fracture during processing and the fibre/matrix bonding affinity. The fibre length distribution was correlated with the results from the melt flow experiments, and the structure–property relationships were determined using SEM images. It was confirmed that the fibre texture, interactions between fibres and fibre–matrix bonding are influenced by subsequent processing steps and have a substantial effect on the further composite melt processing.     

The influence of a thermoplastic toughening interlayer and hydrothermal conditioning on the Mode-II interlaminar fracture toughness of Carbon/Benzoxazine composites

Carbon fibre/Benzoxazine laminates with and without non-woven polyamide (PA) fibre veils at the interlaminar regions were manufactured using vacuum assisted resin transfer moulding (VARTM). The effect of the interlaminar thermoplastic veils on the Mode-II critical strain energy release rate (G_IIC), under both wet and dry conditions, was determined using two commercially available Benzoxazine resins: a toughened system and an untoughened system. In all samples the toughened system outperformed the untoughened system. The overall resistance to Mode-II crack growth was significantly improved by the inclusion of the interlaminar veils due to an increase in the thickness of the matrix-rich interlaminar region, plastic deformation of the PA fibres and a crack-pinning mechanism. Moisture caused an increase in matrix ductility, which improved the resistance to crack initiation; however, this was counteracted by a reduction in fibre/matrix interfacial strength causing a reduction in resistance to crack growth.     

Evaluation on the thermal and mechanical properties of HNT-toughened epoxy/carbon fibre composites

Halloysite nanotubes (HNT) were effectively incorporated into epoxy resin and used for infusion of carbon fibre textiles, resulting in epoxy/halloysite nanotube/carbon fibre (EP/HNT/CF) multi-scale composites. The distribution of nanotubes in the composites was examined by SEM. The thermomechanical properties of the composites were characterized by dynamic mechanical analyser (DMA). A 25% enhancement was recorded for the storage modulus of EP/HNT/CF composite in the glassy state. Moreover, the T_g of the laminates increased with the addition of HNT, and the values were even higher than the T_g of their matrix. Additionally, the Izod impact strength of the composites has been improved. These results indicate a synergistic effect between HNT and carbon fibres.     

CF/EP composite laminates with carbon black and copper chloride for improved electrical conductivity and interlaminar fracture toughness

An experimental study was conducted to improve the electrical conductivity of continuous carbon fibre/epoxy (CF/EP) composite laminate, with simultaneous improvement in mechanical performance, by incorporating nano-scale carbon black (CB) particles and copper chloride (CC) electrolyte into the epoxy matrix. CF/EP laminates of 65 vol.% of carbon fibres were manufactured using a vacuum-assisted resin infusion (VARI) technique. The effects of CB and the synergy of CB/CC on electrical resistivity, tensile strength and elastic modulus and fracture toughness (K_IC) of the epoxy matrix were experimentally characterised, as well as the transverse tensile modulus and strength, Mode I and Mode II interlaminar fracture toughness of the CF/EP laminates. The results showed that the addition of up to 3.0 wt.% CB in the epoxy matrix, with the assistance of CC, noticeably improved the electrical conductivity of the epoxy and the CF/EP laminates, with mechanical performance also enhanced to a certain extent.