Bio-inspired tapered fibers for composites with superior toughness

The toughness of fiber-reinforced composites largely relies on crack bridging. More specifically, intact fibers left behind the tip of a propagating crack are progressively pulled out of the matrix, dissipating energy which translates into toughness. While short fibers are traditionally straight, recent work has showed that they can be shaped to increase the pullout strength, but not necessarily the energy to pullout. In this work we have modeled, fabricated and tested short fibers with tapered ends inspired from a high-performance natural material: nacre from mollusc shells. The main idea was to duplicate a key mechanism where a slight waviness of the inclusion can generate strain hardening and energy dissipation when the inclusion is pulled out. We have incorporated a similar feature to short fibers, in the form of tapered ends with well defined opening angles. We performed pullout tests on tapered steel fibers in epoxy matrices, which showed that the pullout of tapered fiber dissipates up to 27 times more energy than straight fibers. The experimental results also indicated the existence of an optimum taper angle to maximize work of pullout while preventing the brittle fracture of the matrix. An analytical model was developed to capture the pullout mechanism and the interaction between fiber and matrix. The analytical model can guide the design of tapered fibers by providing predictions on the influence of different parameters.     

Simulation of single fiber pullout response with account of fiber morphology

A finite element model was developed at the single fiber length scale to predict the quasi-static pullout response of individual fibers from cementitious composites. The model accounts for energy dissipation through granular flow of the interfacial transition zone (ITZ) and matrix, plastic work in the fiber, and frictional dissipation at the fiber–ITZ interface. The considered fiber morphology was a triangular cross section that had been uniformly twisted along the fiber length. The model was calibrated to published experimental data for fiber pitches of 12.7 and 38.1 mm/revolution pulled from cement mortar with a 44-MPa unconfined compressive strength. The model was used to investigate slip-hardening behavior, tunneling of the cement mortar, in situ pullout behavior of helically twisted fibers at a crack plane, and provide an alternate explanation for the pullout response of twisted fibers from a 84-MPa unconfined compressive strength matrix containing silica fume. Calculations show that twisted fibers can provide up to 5 times the peak pullout force and 10 times the total work compared with straight fibers and infer work-hardening behavior during fiber pullout. The findings indicate that the tailoring of fiber morphology and control of constituent properties are important avenues for achieving significant improvements in the performance of fiber-reinforced cementitious composites.     

Effect of shrinkage reducing agent on pullout resistance of high-strength steel fibers embedded in ultra-high-performance concrete

The interfacial bond strength of long high-strength steel fibers embedded in ultra-high-performance concrete (UHPC) reinforced with short steel microfibers was investigated by conducting single-fiber pullout tests. In particular, the influence of the addition of a shrinkage-reducing to a UHPC matrix on the pullout resistance of high-strength steel fibers was investigated. The addition of a shrinkage-reducing agent produced a noticeable reduction in the fiber pullout resistance owing to the lower matrix shrinkage, although the reduction of pullout resistance differed according to the type of fiber. Long smooth and twisted steel fibers were highly sensitive to the addition of the shrinkage-reducing agent whereas hooked fibers were not. Among the various high-strength steel fibers tested, twisted steel macrofibers showed the highest interfacial bond resistance, although twisted fibers embedded in UHPC showed slip softening pullout behavior rather than the typical slip hardening behavior observed in mortar.     

Crack/fiber interaction and crack growth resistance behavior in microfiber reinforced mortar specimens

Performance enhancement due to microfibers is well known. However, fracture processes that lead to strain hardening behavior in microfiber reinforced composites are not well understood. Crack growth resistance behavior of mortar reinforced with steel microfibers and polypropylene microfibers was investigated in-situ during load application. The polypropylene fibers were inter-ground in the cement mill to enhance the fiber/matrix interfacial frictional stress. A more homogeneous fiber distribution was observed in the inter-ground polypropylene composites compared to the steel microfiber reinforced composites. In steel microfiber reinforced composites the dominant toughening mechanisms were multiple microcracking and successive debonding along the fiber/matrix interface. Fiber pullout, the dominant mechanism in conventional macrofiber reinforced composites was rarely observed. In-situ observation of crack/fiber interaction in the inter-ground polymer fibers also revealed multiple microcracking along the length of the fibers followed by fiber pullout.     

Investigation of structure,mechanical and tribological properties of short carbon fiber reinforced UHMWPE-matrix composites

Structural, mechanical and tribological properties of composite materials based on ultra-high molecular weight polyethylene reinforced with carbon fibers were investigated. The effect of surface modification of carbon fibers on the interaction at the fiber–matrix interface in UHMWPE based composites was studied. It was found that the thermal oxidation of carbon fibers by air oxygen at 500 °C can significantly enhance the interfacial interaction between the polymer matrix and carbon fibers. This allowed us to form composite materials with improved mechanical and tribological properties.     

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.     

Flexural and impact response of woven glass fiber fabric/polypropylene composites

Impact tests with a falling dart and flexural measurements were carried out on polypropylene based laminates reinforced with glass fibers fabrics. Research has shown that the strong fiber/matrix interface obtained through the use of a compatibilizer increased the mechanical performance of such composite systems. The improved adhesion between fibers and matrix weakly affects the flexural modulus but strongly influences the ultimate properties of the investigated woven fabric composites. In fact, bending tests have shown a clear improvement in the flexural strength for the compatibilized systems, in particular when a high viscosity/high crystallinity polypropylene was used. On the contrary, the low velocity impact tests indicated an opposite dependence on the interface strength, and higher energy absorption in not compatibilized composites was detected. This result has been explained in terms of failure mechanisms at the fiber/matrix interface, which are able to dissipate large amounts of energy through friction phenomena. Pull-out of fibers from the polypropylene matrices have been evidenced by the morphological analysis of fracture surfaces after failure and takes place before the fibers breakage, as confirmed by the evaluation of the ductility index.     

Interface engineering of fiber-reinforced all-oxide composites fabricated by the sol–gel method with fugitive pyrolytic carbon coatings

This paper describes the interface engineering of three–dimensional (3D) Nextel™440 fiber-reinforced aluminosilicate composites fabricated by the sol–gel method with fugitive pyrolytic carbon (PyC) coatings. The coating thickness on the fiber strength, interfacial characteristics and there corresponding effects on mechanical properties of the composites were investigated. The study shows that the fiber strength was influenced by the coating thickness and optimized with the thickness of 0.15 μm. The composites with uncoated fibers showed brittle fracture behavior without fiber pullout because of strong interactions between the fiber and the matrix. However, higher strengths and pseudo-ductile fracture behaviors were obtained in the composites with PyC interphases, where different deflections and branches of propagating cracks and fiber pullout patterns were observed. Moreover, induced fugitive PyC interface conditions have great effects on the density, microstructure and mechanical properties of the resultant composites.     

Mechanical and thermal behavior of non-crimp glass fiber reinforced layered clay/epoxy nanocomposites

Mechanical and thermal properties of non-crimp glass fiber reinforced clay/epoxy nanocomposites were investigated. Clay/epoxy nanocomposite systems were prepared to use as the matrix material for composite laminates. X-ray diffraction results obtained from natural and modified clays indicated that intergallery spacing of the layered clay increases with surface treatment. Tensile tests indicated that clay loading has minor effect on the tensile properties. Flexural properties of laminates were improved by clay addition due to the improved interface between glass fibers and epoxy. Differential scanning calorimetry (DSC) results showed that the modified clay particles affected the glass transition temperatures (T_g) of the nanocomposites. Incorporation of surface treated clay particles increased the dynamic mechanical properties of nanocomposite laminates. It was found that the flame resistance of composites was improved significantly by clay addition into the epoxy matrix.     

Assessment of flexural toughness and impact resistance of bundle-type polyamide fiber-reinforced concrete

This study compares the fiber/matrix bonding strength and flexural properties of bundle-type polyamide fibers to those of hooked-end steel fibers. Their fracture behavior upon impact with a high-velocity projectile is also assessed in terms of penetration depth, crater diameter and rear-side scabbing. The results obtained demonstrate that the bundle-type polyamide fibers undergo fracture without fiber pullout because of the increased interfiber gap and specific surface area for bonding, but exhibit poorer flexural fracture behavior with a lower flexural strength and fracture energy when compared to hooked-end steel fibers. Yet despite this, concrete reinforced with bundle-type fibers is shown to more effectively suppress scabbing during high-velocity impact, which is attributed to a more efficacious dispersion of shock stress due to the increased number of individual fibers.     

Combined effects of fiber/matrix interface and water absorption on the tribological behaviors of water-lubricated polytetrafluoroethylene-based composites reinforced with carbon and basalt fibers

Tribological behaviors of two PTFE-based composites reinforced with carbon fibers and basalt fibers sliding against stainless steel under water lubrication were investigated and compared with those of pure PTFE. Results showed that carbon fibers were well bonded with PTFE matrix by dendritic PTFE nano-ribbons in a Boston ivy-like manner, but the basalt fibers were poorly bonded with the matrix. Due to the great accelerating effect of poor fiber/matrix interfacial adhesion on water absorption, BF/PTFE with the highest crystallinity unexpectedly showed the highest water absorption, resulting in serious matrix plasticization and degradation of fiber/matrix interfacial adhesion. As a result, as the reinforcement failure of basalt fibers occurred, BF/PTFE exhibited the highest wear rate. Instead, because good fiber/matrix interfacial adhesion was favor of the resistance to water intrusion, CF/PTFE composite was not dominated by remarkable matrix plasticization and fiber/matrix interface degradation, and showed the lowest wear rate.     

Comparative electromechanical damage-sensing behaviors of six strain-hardening steel fiber-reinforced cementitious composites under direct tension

This research investigates the electromechanical damage-sensing behavior of strain-hardening steel fiber-reinforced cement composites (SH-SFRCs) with six types of steel fibers (1.5% volume fraction content) within an identical mortar matrix (90 MPa). The six types of steel fibers studied are long twisted (T30/0.3), long smooth (S30/0.3), long hooked (H30/0.375), medium twisted (T20/0.2), medium smooth (S19/0.2), and short smooth (S13/0.2) steel fibers. The damage-sensing behavior was evaluated by measuring the changes in the electrical resistance during direct tensile tests. The electrical resistivity of the SH-SFRCs clearly decreased as the tensile strain increased until the post-cracking point, owing to the generation of multiple micro-cracks during strain-hardening. All the SH-SFRCs investigated had nominal gauge factors ranging between 50 and 140; these values are much higher than the commercially conventional gauge factor, which involves metal and is around 2. Both T30/0.3 and T20/0.2 produced the highest gauge factor, i.e., the best damage-sensing capacity, whereas S13/0.2 produced the highest electrical conductivity.     

Interfacial shear strength estimates of NiTi–Al matrix composites fabricated via ultrasonic additive manufacturing

The purpose of this study is to understand and improve the interfacial shear strength of metal matrix composites fabricated via ultrasonic additive manufacturing (UAM). NiTi–Al composites can exhibit dramatically lower thermal expansion compared to aluminum, yet blocking stresses developed during thermal cycling have been found to degrade and eventually cause interface failure in these composites. In this study, the strength of the interface was characterized with pullout tests. Since adhered aluminum was consistently observed on all pullout samples, the matrix yielded prior to the interface breaking. Measured pullout loads were utilized as an input to a finite element model for stress and shear lag analysis. The aluminum matrix experiences a calculated peak shear stress near 230 MPa, which is above its ultimate shear strength of 150–200 MPa thus corroborating the experimentally-observed matrix failure. The influence of various fiber surface treatments and consolidation characteristics on bond mechanisms was studied with scanning electron microscopy, energy dispersive X-ray spectroscopy, optical microscopy, and focused ion beam microscopy.     

Interfacially reinforced methylphenylsilicone resin composites by chemically grafting multiwall carbon nanotubes onto carbon fibers

Both silane and multiwall carbon nanotubes (CNTs) were grafted successfully onto carbon fibers (CFs) to enhance the interfacial strength of CFs reinforced methylphenylsilicone resin (MPSR) composites. The microstructure, interfacial properties, impact toughness and heat resistance of CFs before and after modification were investigated. Experimental results revealed that CNTs were grafted uniformly onto CFs using 3-aminopropyltriethoxysilane (APS) as the bridging agent. The wettability and surface energy of the obtained hybrid fiber (CF-APS-CNT) were increased obviously in comparison with those of the untreated-CF. The CF-APS-CNT composites showed simultaneously remarkable enhancement in interlaminar shear strength (ILSS) and impact toughness. Moreover, the interfacial reinforcing and toughening mechanisms were also discussed. In addition, Thermogravimetric analysis and thermal oxygen aging experiments indicated a remarkable improvement in the thermal stability and heat oxidation resistance of composites by the introduction of APS and CNTs. We believe the facile and effective method may provide a novel interface design strategy for developing multifunctional fibers.     

Experimental study of high electric current effects in carbon/epoxy composites

Electrical and thermal behavior of the carbon fiber-reinforced epoxy composites subjected to relatively high (up to 75 A) steady electric currents is studied. A fully automated experimental setup for real time measurements of the electric current, resistance, voltage, and temperature in carbon fiber-reinforced epoxy matrix composites has been developed. A series of electrical characterization tests on IM7/977-3 unidirectional and symmetric cross-ply composite laminates have been performed and the effects of electric current magnitude and duration, electrical resistance, and associated thermal effects have been investigated. It is determined that electrical resistance exhibits time-dependent behavior. It is also found that application of an electric current leads to a significant temperature rise in the composites that is a result of the intense Joule heat produced in the electrically conductive carbon fibers as well as in the composite-electrode contact.     

Numerical simulations of fracture-toughness improvement using short shaped head ductile fibers

Fibers can be shaped so as to anchor inside the matrix and resist pullout at a crack face, thus improving the fracture-toughness of the composites. This anchoring ability enables a greatly improved utilization of the plastic potential of ductile fibers, increasing fracture-toughness while maintaining stiffness. The purpose of this paper is to explore this property of shaped head fibers for composites with weak fiber–matrix bonding. Because of the difficulty in estimating the fracture-toughness contribution of shaped head fibers analytically or experimentally, we use a FEM based numerical scheme to investigate stress profiles induced during pullout of two chosen shaped head families. Annealed copper fiber with a large residual plastic potential and an elastic epoxy matrix have been used as representative materials. Using the computed strain energy distribution in the matrix as a measure of fracture-toughness contribution, we find that flat-head fibers out-perform ball-head fibers in minimizing failure potential. We have further discovered that within each shape family there exist optimal shapes. The optimal shape for the flat-head family is also computed for the example material system.     

Aspect ratio requirements for nanotube-reinforced, polymer–matrix composites

A fiber’s efficiency in a short-fiber composite can be accurately solved by shear-lag methods, which can account for fiber geometry, an imperfect interface (or interphase), and extend to low volume fractions. Such an analysis was used to evaluate the aspect ratio requirements for single-walled nanotubes (SWNT) in a polymeric composite and contrast it to conventional fibers. The aspect ratio requirements are indistinguishable among all stiff fibers, except at low volume fractions where stiffer fibers require higher aspect ratios. The required aspect ratio decreases significantly at higher volume fractions. A scaling effect in the interphase term implies the interphase is more important for nano-fibers than for larger fibers. If the interface between nano-fibers and the matrix is not excellent, those fibers will not provide effective reinforcement. The most promising SWNT composites should use higher volume fractions and focus on systems where the fiber can stiffen the matrix in the interphase region.     

Surface and sub-surface degradation of unidirectional carbon fiber reinforced epoxy composites under dry and wet reciprocating sliding

The role of water on the sub-surface degradation of unidirectional carbon fiber reinforced epoxy composite is examined. The correlation between the debonding of carbon fibers at the fiber–epoxy interface, and the wear behavior of the carbon fiber composite are discussed based on an in-depth analysis of the worn surfaces. We demonstrate that a reciprocating sliding performed along an anti-parallel direction to the fiber orientation under dry conditions results in a large degradation by debonding and breaking of the carbon fibers compared to sliding in parallel and perpendicular directions. Immersion in water has a harmful effect on the wear resistance of the carbon fiber composite. The competition between crack growth and the wear rate of epoxy matrix and/or carbon fibers in the sliding track determines the level of material loss of the composite in both test environments.     

An investigation of contact resistance between carbon fiber/epoxy composite laminate and printed silver electrode for damage monitoring

An addressable conducting network (ACN) enables the structural condition to be monitored by the electrical resistance between electrodes on surface of CFRP (carbon fiber reinforced polymer) structure. To improve the reliability of ACN for damage detection, the contact resistance between the electrodes and CFRP laminates needs to be minimized. In this paper, the silver nanoparticles electrodes were fabricated via printed electronics techniques on CFRP composite. The contact resistance between the silver electrodes and CFRP was measured with respect to various fabrication conditions such as the sintering temperature of silver nanoink and the surface roughness of CFRP laminates. The interfaces between silver electrode and carbon fibers were observed using scanning electron microscope (SEM). From the study, it was found that the lowest contact resistance of 0.3664 Ω could be achieved when the sintering temperature of the silver nanoink and surface roughness were 120 °C and 230 nm, respectively.     

Hybrid effect of nanoparticles with carbon fibers on the mechanical and wear properties of polymer composites

Polyetheretherketone (PEEK) composites reinforced with carbon fibers (CFs) and nano-ZrO₂ particles were prepared by incorporating nanoparticles into PEEK/CF composites via twin-screw extrusion. The effects of nanoparticles on the mechanical and wear properties of the PEEK/CF composites were studied. The results showed that the incorporation of nano-ZrO₂ particles with carbon fiber could effectively enhance the tensile properties of the composites. The tensile strength and Young’s modulus of the composites increased with the increasing nano-ZrO₂ content. The enhancement effect of the particle was more significant in the hybrid reinforced composites. The compounding of the two fillers also remarkably improved the wear resistance of the composites under water condition especially under high pressures. It was revealed that the excellent wear resistance of the PEEK/CF/ZrO₂ composites was due to a synergy effect between the nano-ZrO₂ particles and CF. CF carried the majority of load during sliding process and prevented severe wear to the matrix. The incorporation of nano-ZrO₂ effectively inhibited the CF failures through reducing the stress concentration on the carbon fibers interface and the shear stress between two sliding surfaces. It was also indicated that the wear rates of the hybrid composites decreased with the increasing applied load and sliding distance under water lubrication. And low friction coefficient and low wear rate could be achieved at high sliding velocity.