Crashworthiness characteristics of a carbon fiber reinforced dual-phase epoxy–polyurea hybrid matrix composite

The crashworthiness characteristics of rectangular tubes made from a Carbon-fiber reinforced Hybrid-Polymeric Matrix (CHMC) composite were investigated using quasi-static and impact crush tests. The hybrid matrix formulation of the CHMC was created by combining an epoxy-based thermosetting polymer with a lightly crosslinked polyurea elastomer at various cure-time intervals and volumetric ratios. The load–displacement responses of both CHMC and carbon-fiber reinforced epoxy (CF/epoxy) specimens were obtained under various crushing speeds; and crashworthiness parameters, such as the average crushing force and specific energy absorption (SEA), were calculated using subsequent load–displacement relationships. The CHMC maintained a high level of structural integrity and post-crush performance, relative to traditional CF/epoxy. The influence of the curing time and volumetric ratios of the polyurea/epoxy dual-hybridized matrix system on the crashworthiness parameters was also investigated. The results reveal that the load carrying capacity and total energy absorption tend to increase with greater polyurea thickness and lower elapsed reaction curing time of the epoxy although this is typically a function of the loading rate. Finally, the mechanism by which the CHMC provides increased damage tolerance was also investigated using scanning electron microscopy (SEM).     

I–V characteristics and electro-mechanical response of different carbon black/epoxy composites

I–V characteristics and electro-mechanical response of carbon black (CB)/epoxy composites were studied experimentally. Two types of CB were used in the experiment, they were: sprayed CB and conductive CB particles. During the experiment, it was found that the I–V characteristics of the composites and their electro-mechanical response were greatly affected by the particle size of CB as well as their dispersion properties. The epoxy containing sprayed CB with the diameter of 123 nm composites gave predicted relationships, in terms of I–V characteristics and strain/electrical resistivity once they were subjected to a compressive load. The electrical breakdown assumption incorporated in the DC circuit model is proposed in this paper to interpret the response of the composites with different types of CB particles.     

Drop-weight impact of plain-woven hybrid glass–graphite/toughened epoxy composites

The progressive damage behaviors of hybrid woven composite panels (101.6 mm × 101.6 mm) impacted by drop-weights at four different velocities were studied by a combined experimental and 3-D dynamic nonlinear finite element approach. The specimens tested were made of plain-weave hybrid S2 glass-IM7 graphite fibers/toughened epoxy (cured at 177 °C). The composite panels were damaged using a pressure-assisted Instron-Dynatup 8520 instrumented drop-weight impact tester. During these low-velocity simpact tests, the time-histories of impact-induced dynamic strains and impact forces were recorded. The damaged specimens were inspected visually and using ultrasonic C-Scan methods. The commercially available 3-D dynamic nonlinear finite element (FE) software, LS-DYNA, incorporated with a proposed user-defined damage-induced nonlinear orthotropic model, was then used to simulate the experimental results of drop-weight tests. Good agreement between experimental and FE results has been achieved when comparing dynamic force, strain histories and damage patterns from experimental measurements and FE simulations.     

Electrical thermal heating and piezoresistive characteristics of hybrid CuO–woven carbon fiber/vinyl ester composite laminates

The electric heating and piezoresistive characteristics of CuO–woven carbon fiber (CuO–WCF) composite laminates were experimentally evaluated. Hybrid CuO–WCF composites were fabricated via a two-step seed-mediated hydrothermal method. The interlaminar interface between two plies of hybrid CuO–WCF/vinyl ester composite laminae was influenced by interlocked fiber–fiber cross-linking structures with CuO NRs and acted as electric heating and resistance elements. The contribution of CuO NRs (10–110 mM) to the interlaminar interface was determined by measuring the temperature profile, in order to investigate the electrical resistive heating behavior. At higher concentration of CuO NRs growth in the interlaminar region applied by 3 A, the average temperature reached to 83.55 °C at the interface area 50 × 50 mm² and the heating efficiency was 0.133 W/°C owing to radiation and convection given by 10.5 W (3 A, 3.5 V). To investigate the piezoresistive response, the through-thickness gauge factor was observed at 0.312 during Joule heating applied by 2 A, compared with 0.639 at an ambient air temperature for CuO 110 mM concentration. The morphology and crystallinity of CuO NRs were investigated using scanning electron microscopy and X-ray diffraction analyses, respectively. The temperature dependence of hybrid CuO–WCF composite laminates’ storage moduli were analyzed using a dynamic mechanical analyzer. These characterizations showed that the interlaminar interface, combined with the high specific surface area of CuO NRs, provided the electron traps for electrical conduction around multiple WCF junctions and adjacent cross-linked laminae.     

Tribological performance of carbon nanotube–graphene oxide hybrid/epoxy composites

An investigation is conducted on the effect of the hybrid of multi-wall carbon nanotubes (MWCNTs) and graphene oxide (GO) nanosheets on the tribological performance of epoxy composites at low GO weight fractions of 0.05–0.5 phr. The MWCNT amount is kept constant at 0.5 phr, which is typical for CNT/epoxy composites with enhanced mechanical properties. Friction and wear tests against smooth steel show that the introduction of 0.5 phr MWCNTs into the epoxy matrix increases the friction coefficient and decreases the specific wear rate. When testing the tribological performance of MWCNT/GO hybrids, it is shown that at a high GO amount of 0.5 phr, the friction coefficient is decreased below that of the neat matrix whereas the wear rate is increased above that of the neat matrix. At an optimal hybrid formulation, i.e., 0.5 phr MWCNTs and 0.1 phr GO, a further increase in the friction coefficient and a further reduction in the specific wear rate are observed. The specific wear rate is reduced by about 40% down to a factor of 11 relative to the neat epoxy when the GO content is 0.1 phr.     

Strengthening in and fracture behaviour of CNT and carbon-fibre-reinforced epoxy–matrix hybrid composite

Advanced materials such as continuous fibre-reinforced polymer matrix composites offer significant enhancements in strength and fracture resistance properties as compared with their bulk, monolithic counterparts. In the present work, mode-I (tensile) fracture behaviour of the neat epoxy (without nano- or hybrid reinforcements), nanocomposite (with amino-functionalized multi-walled carbon nanotube (MWCNT) reinforcement to neat epoxy) and hybrid composite (with amino MWCNT and carbon fibre reinforcements to neat epoxy) along with their flexural strength and interlaminar shear strength has been reported and discussed. Limited topological studies have also been conducted to understand the nature of material fracture and its dependence on the notch orientation. The results thus obtained are analysed and discussed in detail to elucidate: (i) alignment of fibre and its influence on the anisotropy in strength and fracture resistance, (ii) dependence of notch root radii on the apparent fracture toughness and concurrence to strain-controlled fracture and (iii) finally, the nature of J–R curves. The results thus obtained have revealed that the resistance to fracture is significantly increased with the addition of amino-functionalized MWCNTs and carbon fibres. In the hybrid composite, fracture resistance is greater in the longitudinal orientation of fibres than in the transverse orientation and it exhibits a significantly higher strength–fracture toughness combination.     

A comparative study on erosion characteristics of red mud filled bamboo–epoxy and glass–epoxy composites

Bamboo fiber reinforced epoxy matrix composites filled with different weight proportions of red mud (a solid waste generated in alumina plants) are fabricated. The mechanical properties of these composites are evaluated and are then compared with those of a similar set of glass–epoxy composites. The solid particle erosion characteristics of the bamboo–epoxy composites have been studied and the experimental results are compared with those for glass–epoxy composites under similar test conditions available in the published literature. For this, an air jet type erosion test rig and Taguchi orthogonal arrays have been used. The methodology based on Taguchi’s experimental design approach is employed to make a parametric analysis of erosion wear process. This systematic experimentation has led to determination of significant process parameters and material variables that predominantly influence the wear rate of the particulate filled composites reinforced with bamboo and glass fiber, respectively. The comparative study indicates that although the bamboo based composites exhibit relatively inferior mechanical properties, their erosion wear performance is better than that of the glass fiber reinforced composites. It further indicates that the incorporation of red mud particulates results in improvement of erosion wear resistance of both the bamboo and glass fiber composites.     

Strength and damage tolerance of composite–composite joints with steel and titanium through the thickness reinforcements

Today’s aeronautic, automotive and marine industry is in demand of structurally efficient, low weight alternatives for composite–composite joints which combine the advantages of low weight input of adhesively bonded joints and high damage tolerance of through the thickness bolted joints. In the present work, composite–composite joints are reinforced through the thickness by thin metal inserts carrying cold metal transfer welded pins (CMT pins). The influence of pin alignment and type of pin on the damage tolerance of single lap shear (SLS) composite–composite joints is investigated. The use of titanium reinforcements is evaluated and compared to stainless steel reinforced, adhesively bonded and co-cured specimens. A detailed analysis of the stress–strain behavior is given and the stiffness and energy absorption of the SLS joints during tensile loading is assessed. The results show that joints reinforced with CMT pins absorb significantly higher amounts of energy, when compared to adhesively bonded and co-cured joints.     

Seawater effect on impact behavior of glass–epoxy composite pipes

The effect of seawater immersion on impact behavior of glass–epoxy composite pipes is experimentally investigated. Glass–epoxy pipes with [±55°]₃ orientation were fabricated using filament winding method. Composite pipes were selected for four different diameters as 50 mm, 75 mm, 100 mm, and 150 mm. The pipes were immersed in artificial seawater having a salinity of about 3.5% for 3, 6, 9, and 12 months in laboratory conditions. At the end of the conditioning period, the specimens were impacted at three distinct energy levels as 15 J, 20 J, and 25 J at ambient temperature of 20 °C. The comparisons between the dry and immersed cases were carried out by using contact force, deflection and absorbed energy data of the impact tests. Results show that moisture absorption, salt in seawater, diameter of specimen and residual stresses produced by manufacturing process of the composite pipe have significant effect on maximum contact force, maximum deflection, absorbed energy and failure of composite pipes according to exposure time to seawater.     

Fatigue damage of carbon–epoxy laminates with embedded optical fibres

Abstract

The present paper is concerned with the fatigue behaviour ofcarbon-epoxy laminates with embedded optical fibres subjected to bending loads. The main goal of this investigation was to evaluate quantitatively the effect of the presence of optical fibres within the host structure on its whole fatigue behaviour. Two optical fibre positions were investigated: in the mid-plane of the laminate and near the surface subjected to loading. Two distinct geometries of the ply stacking sequence were also considered, namely unidirectional and crossply. In order to evaluate the fatigue life and the fatigue damage, two different loading levels were used, both at 6 Hz frequency, room temperature and R = 0.1. Fatigue damage was monitored using dynamic stiffness decay and acoustic emission techniques. Failure mechanisms were analysed by means of optical and scanning microscopy. The results obtained lead to the conclusion that the embedding of optical fibres markedly prejudices the fatigue performance of the material only for certain configurations. It was also possible to speculate on the fatigue failure mechanisms, and to relate them with relevant experimental parameters, such as the lay-up geometry and optical fibre position.     

Prediction of low velocity impact damage in carbon–epoxy laminates

It is well known that composite laminates are easily damaged by low velocity impact. This event causes internal delaminations that can drastically reduce the compressive strength of laminates. In this study, numerical and experimental analyses for predicting the damage in carbon–epoxy laminates, subjected to low velocity impact, were performed. Two different laminates (0₄,90₄)_s and (0₂,±45₂,90₂)_s were tested using a drop weight testing machine. Damage characterisation was carried out using X-rays radiography and the deply technique. The developed numerical model is based on a special shell finite element that guarantees interlaminar shear stresses continuity between different oriented layers, which was considered fundamental to predict delaminations. In order to predict the occurrence of matrix failure and the delaminated areas, a new failure criterion based on experimental observations and on other developed criteria, is included. A good agreement between experimental and numerical analysis for shape and orientation of delaminations was obtained. For delaminated areas, reasonable agreement was obtained.     

Tensile strength of glass fibres with carbon nanotube–epoxy nanocomposite coating

A study has been made of a concept of ‘healing’ coatings applied onto the brittle fibre surface to reduce the stress concentrations and thus to improve the reinforcing efficiency in a composite. Coatings made from neat epoxy and carbon nanotube (CNT) reinforced epoxy nanocomposite were applied onto the individual glass fibres as well as rovings. It is shown that the 0.3 wt.% CNT–epoxy nanocomposite coating gave rise to a significant increase in tensile strength of the single fibre for all gauge lengths, better than the neat epoxy coating. The results on glass fibre roving also indicated a clear beneficial effect of nanocomposite impregnation on tensile strength. The rovings impregnated with the CNT nanocomposite exhibited a more uniform strength distribution and higher strengths than those impregnated with the neat epoxy. The changes in prevailing failure mechanisms influenced by the epoxy and nanocomposite coatings have been identified.     

Simulated strength and structure of carbon–carbon reinforced composite

The atomistic simulations of carbon nanotube (CNT) – carbon reinforced composite material are reported. The studied composite samples are obtained by impregnating certain amounts of CNTs (3,3) and (6,6) into a pristine graphite matrix. The addition of CNTs is found to be of significant usefulness for the CNT–reinforced composites, since it allows to achieve extreme lightness and strength. Being impregnated into graphite matrix, CNTs are able to increase the critical component of its initially highly anisotropic Young modulus by 2–8 times. The linear thermal expansion coefficients do not exceed 10⁻⁶ to 10⁻⁵ K⁻¹, making this material applicable for novel aviation and space vehicles. The degree of dispersion of CNTs within graphite matrix is found to drastically influence composite properties.     

Abrasive wear behaviour of hard powders filled glass fabric–epoxy hybrid composites

The effect of incorporation of tungsten carbide (WC) and tantalum niobium carbide (Ta/NbC) powders on three-body abrasive wear behaviour in glass fabric–epoxy (G–E) composites was investigated and findings are analysed. A vacuum assisted resin transfer moulding (VARTM) technique was employed to obtain a series of G–E composites containing different fillers (WC and WC + Ta/NbC). Dry sand rubber wheel abrasion test was carried out at 200 rpm speed. The effect of different loads (22 and 32 N) and abrading distances (from 135 to 540 m) on the performance of the wear resistance were measured. The wear volume loss of the composites was found increasing with the increase in abrading distances and under the same conditions the specific wear rate decreases. The hard powders filled G–E composite systems exhibit lower wear volume loss and lower specific wear rate as compared to unfilled G–E composite system. The features of worn surfaces of the specimen were evaluated at higher and lower abrading distances at load of 32 N were using scanning electron microscope (SEM) and results indicate more severe damage to matrix and glass fiber in unfilled composite system as compared to hard powder filled composites.     

The preparation and mechanical properties of carbon–carbon/lithium–aluminum–silicate composite joints

Silica carbide modified carbon cloth laminated C–C composites have been successfully joined to lithium–aluminum–silicate (LAS) glass–ceramics using magnesium–aluminum–silicate (MAS) glass–ceramics as interlayer by vacuum hot-press technique. The microstructure, mechanical properties and fracture mechanism of C–C/LAS composite joints were investigated. SiC coating modified the wettability between C–C composites and LAS glass–ceramics. Three continuous and homogenous interfaces (i.e. C–C/SiC, SiC/MAS and MAS/LAS) were formed by element interdiffusions and chemical reactions, which lead to a smooth transition from C–C composites to LAS glass–ceramics. The C–C/LAS joints have superior flexural property with a quasi-ductile behavior. The average flexural strength of C–C/LAS joints can be up to 140.26 MPa and 160.02 MPa at 25 °C and 800 °C, respectively. The average shear strength of C–C/LAS joints achieves 21.01 MPa and the joints are apt to fracture along the SiC/MAS interface. The high retention of mechanical properties at 800 °C makes the joints to be potentially used in a broad temperature range as structural components.     

Design of μ-CNC machining centre with carbon/epoxy composite–aluminium hybrid structures containing friction layers for high damping capacity

The focus of this paper is on the design of machine tool structures, such as columns and spindle holders, for a 3-axis μ-CNC machining centre. Carbon/epoxy composite–aluminium hybrid structures with friction layers were used to increase structural damping. Two types of hybrid column structures were proposed. Finite element analyses were carried out to calculate both the static deflection of columns due to deadweight and also the first natural frequency of machine tool structures as a function of the stacking angle and thickness of the carbon/epoxy composites. To increase damping capacity, a friction layer was inserted between the aluminium-composite interface. For the design of the structures the stacking angle and the thickness ratio of the composites were considered as major design variables. And the most appropriate stacking sequence of the composite–aluminium hybrid structure employing a friction layer was determined using finite element analyses and vibration tests.     

Meso-scale strain localization and failure response of an orthotropic woven glass–fiber reinforced composite

The present work focuses on studying the multi-scale deformation and failure mechanisms of an orthogonally woven glass fiber reinforced composite as a function of fiber orientation angle using digital image correlation. The full-field displacement and strain localization are effectively captured at meso-scale. At continuum scale, a remarkable change in mechanical response is observed when the loading axis diverges from principal axes. The variation in the global mechanical response is observed to be most prominent in the change of stiffness and strain at failure. At meso scale, a high degree of local deformation heterogeneity is observed and the level of inhomogeneity is found to be more prominent in case of the 45° off-axis specimens. While fiber-pull out is the major failure mode in the case of specimen loaded parallel to 0° and 90° fiber orientation, the localized shear strain developed in polymer-rich regions is the driving failure cause in the case of 45° off-axis specimen.     

Effects of carbon nanotube enrichment of epoxy resins on hybrid FRP–FR confinement of concrete

The present research study is focused on the tensile testing and mechanical characterization of three different epoxy resins, reinforced with different concentrations of Multi-Walled Carbon Nanotubes (MWCNTs). The resins are used in crack repair of concrete members as well as in FRP sheet wrapping. The CNT reinforced polymers (CNTRP) showed a remarkable enhancement of their tensile strength (2.25 times over the host matrix) and deformation at failure (3.27 times over the host matrix). The CNTRP with the highest viscosity were used in a structural application, to impregnate glass FRP sheets to confine concrete cylinders. Then the specimens were wrapped with non-impregnated polypropylene fiber ropes (PPFR). The comparative results between specimens confined by the hybrid system, including glass sheets impregnated with epoxy resin or with resin reinforced by CNTs (CNTRP), are discussed. The specimen with CNT reinforced polymer showed 7.5% higher bearing load of the concrete until failure of the glass sheet, over the column with non-reinforced polymer. The gradual, smooth failure of the glass fiber CNTRP jacket took place at higher load levels than GFRP. Moreover, it presented half temporary load loss after the fracture of the glass sheet than the GFRP strengthened column. Finally, it indicated an earlier stabilization and regaining of the bearing load (27% earlier in terms of axial strain).     

Modelling of carbon–carbon composite manufacturing processes

This paper is devoted to the modelling of technological processes of manufacturing of siliconized carbon–carbon composites. The developed model describes the changes that occur in the properties of the composites (strength, elastic moduli, shrinkage) during the technological cycle of manufacturing and also the residual stresses generated in composite structures. It is shown that the level of the residual stresses and the character of changes in the properties of carbon–carbon composites essentially differ from those of polymer–matrix composites.