The tensile fatigue behaviour of a silica nanoparticle-modified glass fibre reinforced epoxy composite

An anhydride-cured thermosetting epoxy polymer was modified by incorporating 10 wt.% of well-dispersed silica nanoparticles. The stress-controlled tensile fatigue behaviour at a stress ratio of R = 0.1 was investigated for bulk specimens of the neat and the nanoparticle-modified epoxy. The addition of the silica nanoparticles increased the fatigue life by about three to four times. The neat and the nanoparticle-modified epoxy resins were used to fabricate glass fibre reinforced plastic (GFRP) composite laminates by resin infusion under flexible tooling (RIFT) technique. Tensile fatigue tests were performed on these composites, during which the matrix cracking and stiffness degradation was monitored. The fatigue life of the GFRP composite was increased by about three to four times due to the silica nanoparticles. Suppressed matrix cracking and reduced crack propagation rate in the nanoparticle-modified matrix were observed to contribute towards the enhanced fatigue life of the GFRP composite employing silica nanoparticle-modified epoxy matrix.     

Interlaminar reinforcement of glass fiber/epoxy composites with graphene nanoplatelets

This work investigated the ability of graphene nanoplatelets (GnPs) to improve the interlaminar mechanical properties of glass-reinforced multilayer composites. A novel method was developed for the inclusion of GnPs into the interlaminar regions of plain-weave, glass fabric fiber-reinforced/epoxy polymer composites processed with vacuum assisted resin transfer molding. Flexural tests showed a 29% improvement in flexural strength with the addition of only 0.25 wt% GnP. At the same concentration, mode-I fracture toughness testing revealed a 25% improvement. Additionally, low-velocity drop weight impact testing showed improved energy absorption capability with increasing concentration of GnPs. Ultrasonic C-scans and dye penetration inspection of the impact- and back-sides of the specimens qualitatively support these results. Finally, the impact damage area was quantified from the C-scan data. These results showed that the impact-side damage area decreased with increasing concentration of GnP, while the back-side damage area increased.     

A magnesium alloy matrix composite reinforced with metallic glass

Novel light-weight materials of advanced performance are now experiencing global interest due to the strong need to reduce energy consumption in land and air transportation sectors. Here we report on a novel magnesium alloy matrix composite material. The reinforcing phase in the magnesium alloy is a fine dispersion of metallic glass particles. The composite is sintered from the powder mixture of the alloy and metallic glass at a temperature slightly above the glass transition T_g of the metallic glass particles that is close to the Mg alloy’s solidus temperature. At the compaction temperature, the metallic glass acts as a soft liquid-like binder but upon cooling it becomes the hard reinforcement component of the composite. Processing, microstructure and mechanical properties of the composite are discussed.     

Synergistic effects of PEK-C/VGCNF composite nanofibres on a trifunctional epoxy resin

Polyetherketone cardo (PEK-C) nanofibres containing vapour-grown carbon nanofibres (VGCNFs) were electrospun, and used for toughening and reinforcing a triglycidyl amino phenol (TGAP) epoxy resin. The addition of PEK-C/VGCNF nanofibres to the epoxy resin led to the distribution of VGCNFs primarily within the phase separated PEK-C-rich domains. Synergistic effects of thermoplastic PEK-C and VGCNFs on the mechanical properties, phase morphologies and thermal stability of the resultant epoxy matrix composites were observed when the PEK-C/CNF nanofibres were blended at a low content into the epoxy resin. Strong and tough multifunctional nanocomposites were prepared with the addition of 5 wt.% PEK-C/CNF nanofibres to the epoxy matrix.     

Phenoxy nanocomposite carriers for delivery of nanofillers in epoxy matrix for resin transfer molding (RTM)-manufactured composites

The use of phenoxy nanocomposite films as carriers of nanofillers involving multiwalled carbon nanotubes and nanoclays is successfully demonstrated for application in epoxy carbon fibers reinforced composites (CFRC) processed by RTM. Model studies on individual nanocomposite filaments embedded in epoxy precursors show that the nanofillers are passively transported by the interdiffusion gradient during heating over distance around 800 μm. A morphology gradient is generated after reaction induced phase separation and the nanofillers end up in the epoxy, despite their initial dispersion in the phenoxy. The proof of concept is extended to CFRC panels where nanocomposite phenoxy films are prepositioned between every odd carbon layer of the preform. Carbon nanotubes are filtered by the carbon fabrics, which limits their full diffusion and that of phenoxy through the preform. This has negative consequences on fracture toughness (G_Ic)_. For nanoclay, G_Ic is rather slightly improved although the origin is not fully clear.     

Eliminating volatile-induced surface porosity during resin transfer molding of a benzoxazine/epoxy blend

We studied the mechanism of volatile-induced surface porosity formation during the resin transfer molding (RTM) of aerospace composites using a blended benzoxazine/epoxy resin, and identified reduction strategies based on material and processing parameters. First, the influence of viscosity and pressure on resin volatilization were determined. Then, in situ data was collected during molding using a lab-scale RTM system for different cure cycles and catalyst concentrations. Finally, the surface quality of molded samples was evaluated. The results show that surface porosity occurs when cure shrinkage causes a sufficient decrease in cavity pressure prior to resin vitrification. The combination of thermal gradients and rapid gelation can generate large spatial variations in viscosity, rendering the coldest regions of a mold susceptible to porosity formation. However, material and cure cycle modifications can alter the resin cure kinetics, making it possible to delay the pressure drop until higher viscosities are attained to minimize porosity formation.     

Torsion fatigue behavior of unidirectional carbon/epoxy and glass/epoxy composites

This paper presents results of the feasibility of carbon/epoxy composites (CFRP) as a future helicopter flexbeam material. Torsional behaviors of unidirectional CFRP and glass/epoxy composites (GFRP) with the same resin matrix were investigated. The initial torsional rigidity of CFRP was almost identical to that of GFRP. The torsional rigidities calculated using finite element analyses (FEA) agreed with the experimental results: the torsional rigidities are governed mainly by the material’s shear stiffness. Torsion fatigue tests were also conducted by controlling the angle of twist of the sinusoidal wave under a constant tensile axial load. No catastrophic failure occurred with either GFRP or CFRP, although decreased amplitudes of torque and torsional rigidities were observed according to the number of cycles. Results of X-ray CT inspections and numerical calculation by FEA revealed that degradation of a torsional rigidity is caused mainly by splitting crack propagation along the fiber direction. The torsion fatigue life of CFRP was superior to that of GFRP. Consequently, results confirmed that CFRP exhibits excellent properties as a torsional element of a helicopter flexbeam in terms of torsional rigidity and tension–torsion fatigue behaviors.     

Fabrication of transparent conductive carbon nanotubes/polyurethane-urea composite films by solvent evaporation-induced self-assembly (EISA)

Transparent and conductive carbon nanotubes (CNTs)/polyurethane-urea (PUU) composite films were prepared by solvent evaporation-induced self-assembly (EISA). Pristine CNTs were treated with acids (H₂SO₄/HNO₃ = 3:1, v:v), acylated with thionyl chloride, and purified after filtration. These acylated CNTs (0.05 wt.% in dimethylformamide, DMF) were deposited onto the 3-aminopropyl triethoxysilane (APTES)-modified glass substrate by DMF EISA at 100 °C with the withdrawal rate of 3 cm/h. The CNT layers of 200–400 nm thicknesses were transferred to the PUU films by solution casting or resin transfer molding (RTM) at ambient temperature. Optical transmittances of the composite films were 60–75% at 550 nm wavelength and their sheet resistances were 5.2 × 10⁰–2.4 × 10³ kΩ/square, and which varied significantly with type of CNTs and the transferring methods of CNT layers.     

Interfacial shear strength of a glass fiber/epoxy bonding in composites modified with carbon nanotubes

In recent years, carbon nanotubes (CNTs) grown on fibers have attracted a lot of interest as an additional reinforcing component in conventional fiber-reinforced composites to improve the properties of the fiber/matrix interface. Due to harsh growth conditions, the CNT-grafted fibers often exhibit degraded tensile properties. In the current study we explore an alternative approach to deliver CNTs to the fiber surface by dispersing CNTs in the fiber sizing formulation. This route takes advantage of the developed techniques for CNT dispersion in resins and introduces no damage to the fibers. We focus on unidirectional glass fiber/epoxy macro-composites where CNTs are introduced in three ways: (1) in the fiber sizing, (2) in the matrix and (3) in the fiber sizing and matrix simultaneously. Interfacial shear strength (IFSS) is investigated using single-fiber push-out microindentation. The results of the test reveal an increase of IFSS in all three cases. The maximum gain (over 90%) is achieved in the composite where CNTs are introduced solely in the fiber sizing.     

Fatigue crack growth behavior of silica particulate reinforced epoxy resin composite

In the present work, fatigue crack growth tests of epoxy resin composite reinforced with silica particle under various R-ratios were carried out to investigate the effect of R-ratio on crack growth behavior and to discuss fatigue crack growth mechanism. Crack growth curves arranged by ΔK showed clear R-ratio dependence even under no crack closure, where the values of ΔK_th were 0.82 and 0.33 MPa √m for R = 0.1 and 0.7 respectively. However, crack growth curves arranged by K_max merged into almost one curve regardless of R-ratio, which indicated that crack growth behavior of the present composite was time-dependent. The value of K_max,th were in the range from 0.78 to 1.12 MPa √m. In situ crack growth observation revealed the crack growth mechanism: micro-cracking near the interface between silica particle and resin matrix occurs ahead of a main crack and then micro-cracks coalesce with a main crack to grow. The crack path was in the epoxy matrix, which was consistent with the time-dependent crack growth.     

Cryogenic delamination growth in woven glass/epoxy composite laminates under mixed-mode I/II fatigue loading

This paper investigates the fatigue delamination growth behavior in woven glass fiber reinforced polymer (GFRP) composite laminates under mixed-mode I/II conditions at cryogenic temperatures. Fatigue delamination tests were performed with the mixed-mode bending (MMB) test apparatus at room temperature, liquid nitrogen temperature (77 K) and liquid helium temperature (4 K), in order to obtain the delamination growth rate as a function of the range of the energy release rate, and the dependence of the delamination growth behavior on the temperature and the mixed-mode ratio of mode I and mode II was examined. The energy release rate was evaluated using three-dimensional finite element analysis. The fractographic examinations by scanning electron microscopy (SEM) were also carried out to assess the mixed-mode fatigue delamination growth mechanisms in the woven GFRP laminates at cryogenic temperatures.     

Demonstration of pseudo-ductility in unidirectional hybrid composites made of discontinuous carbon/epoxy and continuous glass/epoxy plies

A new, partially discontinuous architecture is proposed to improve the mechanical performance of pseudo-ductile, unidirectional (UD) interlayer carbon/glass hybrid composites. The concept was successfully demonstrated in different laminates with high strength and high modulus carbon and S-glass epoxy UD prepregs. The novel hybrid architecture provided pseudo-ductile tensile stress–strain responses with a linear initial part followed by a wide plateau and a second linear part, all connected by smooth transitions. The best hybrid configuration showed 60% improvement in modulus compared to pure glass, 860 MPa plateau stress and 2% pseudo-ductile strain. The initial modulus, the plateau stress and the overall tensile stress–strain response of each specimen configuration were predicted accurately.     

Effect of microwave irradiation on carbon fiber/epoxy resin composite fabricated by vacuum assisted resin transfer molding

The effects of microwave irradiation for resin-curing of carbon fiber/epoxy resin composite (CFRTS), which was fabricated by vacuum-assisted resin transfer molding (VARTM) method, were investigated at 2.45 GHz frequency. The mechanical properties of CFRTS cured by microwave irradiation for 20 min at 120 °C were similar as compared to the conventional oven for 300 min at 120 °C. Moreover, the CFRTS irradiated by microwave had better adherence property between fiber and resin as compared to conventional oven at same resin-curing time. From the relation between resin-curing and mechanical property, it was found that the curing rate of microwave-irradiated CFRTS was 15 times faster as compared to conventional heating. Furthermore, the activation energies for resin-curing reaction on conventional- and microwave-cured CFRTS were estimated to be 2.7 and 1.3 × 10⁴ J/mol, respectively. The resin-curing reaction in CFRTS prepared by VARTM method was significantly promoted by microwave irradiation at short time.     

Modelling flow and filtration in liquid composite moulding of nanoparticle loaded thermosets

This paper presents analytical and numerical models of liquid moulding of hybrid composites. An 1-D analytical solution of Darcy’s problem, accompanied by nanoparticle filtration kinetics and conservation, has been developed. A non-linear finite difference model incorporating variations in permeability, porosity and viscosity as a function of local nanoparticle loading was formulated. Comparison of the two models allowed verification of their validity, whilst a mesh sensitivity study demonstrated the convergence of the numerical scheme. The limits of validity of the analytical solution were established over a range of infiltration lengths and filtration rates for different nanoparticle loadings. The analytical model provides an accurate and efficient approximation of through thickness infusion of hybrid composites, whereas use of the numerical scheme is necessary for accurate simulation of in-plane filling processes. The models developed here can serve as the basis of process design/optimisation for the production of hybrid composites with controlled distribution of nano-reinforcement.     

Effect of rapid curing process on the properties of carbon fiber/epoxy composite fabricated using vacuum assisted resin infusion molding

Long processing cycle makes vacuum assisted resin infusion molding (VARIM) only suitable for low and medium volumes of production, and shortening of curing time is critical to improving the processing efficiency of automotive composite parts. In this paper, unidirectional carbon fiber reinforced composite laminates were fabricated by VARIM. Three different processes (namely quick, quick-post and preheating) were employed, in which a kind of rapid curing epoxy resin is used. The preheating of mold and fiber was conducted to shorten the filling time compared with that of quick process. Quick-post process with a post cure stage was investigated to verify the composite properties fabricated by quick process. The cycle time was 16 min for preheating process, about 30% shorter than that of quick process, simultaneously, flexural strength and interlaminar shear strength (ILSS) were respectively improved by 29% and 7% compared with those of quick process. The non-uniformity of mechanical properties at different positions along resin flow direction under preheating process was found, but the processing quality of composite was good. The preheating process is confirmed to be suitable for the improvement of processing efficiency of VARIM with good mechanical properties. In addition, the composite fabricated by quick-post process has better mechanical properties, which is attributed to the alleviation of residual stress during post curing process.     

Effect of flax fibres individualisation on tensile failure of flax/epoxy unidirectional composite

The study of plant fibres composites is a widespread research topic; nevertheless, the reinforcement mechanism understanding of these materials must be still improved. The paper presents a study of the effect of the mechanical properties, the dispersion and the fibre/matrix interface property of elementary fibres on the tensile properties of unidirectional composites. Our work shows that the mechanical performances of unidirectional composites could be linked to those of the elementary fibres as well as to the composites microstructure. Flax fibres individualisation, linked to the homogeneity of the microstructure, is highly dependent on the fibre extraction process. The importance of the composites homogeneity has been confirmed by the Rosen model, which could be used thanks to interfacial shear strength measurements.     

Simulation of curing process of carbon/epoxy composite during autoclave degassing molding by considering phase changes of epoxy resin

Strain monitoring of a carbon/epoxy composite cross-ply laminate ([0₅/90₅]_s) during thermoforming was conducted by using fiber Bragg grating (FBG) sensors. The entire process was simulated by employing finite element analysis (FEA) by taking into consideration the phase changes of the epoxy resin. For the precise simulation of the curing process, a dielectrometry sensor was used to detect the epoxy-resin dissipation factor, which in turn was used to identify the curing point. To investigate the phase changes and consolidation of the composite laminate by employing FEA, modulus changes with temperature were measured by dynamic mechanical analysis (DMA), and the permeability was estimated by measuring the fiber volume fraction according to the curing temperature. As the epoxy resin changed from a liquid to solid phase, the strain generated along the carbon fibers dynamically changed, and the analysis results generally predicted the strain variation quite well. To apply this simulation technique to practical structures, a composite-aluminum hybrid wheel was analyzed and experimentally verified.     

Investigation of combined stress state failure criterion for glass fiber/epoxy interface by the cruciform specimen method

The interfacial failure criterion under combined stress state in a glass fiber/epoxy composite is investigated by the cruciform specimen method. Experiments were conducted by using specimens with a fiber whose angle from the loading direction is varied in order to make various stress state of normal and shear at the interface. Finite element analysis is performed to calculate the interfacial stress distribution. By combining the experimental measurement of the specimen stress at the interfacial debonding initiation and the finite element stress analysis, it is possible to obtain the interfacial stress state at interfacial failure. A method to determine the interfacial failure criterion and the interfacial failure initiation location simultaneously is proposed in the present study. We conclude the value of the interfacial shear strength is higher than that of the interfacial normal strength for the material system used in the present study.     

Effect of colloidal silica on the strength and energy absorption of glass fiber/epoxy interphases

Prior research has demonstrated that fiber-sizings can be designed to yield composite materials that simultaneously possess high energy absorption and structural properties. The improved mechanical properties resulted from control of the fiber surface chemistry and nano-scale topological features within the fiber–matrix interphase. The present study further explains the role of sizing chemistry and surface roughness on composite material performance. Model and commercial glass fiber epoxy specimens were fabricated using these fiber sizing systems resulting in interphase regions with varied surface topology and chemical functionality. Micromechanical measurements were performed using the microdroplet adhesion test method to quantify the fiber–matrix interfacial properties. Improvement in energy absorption and interfacial shear strength due to the presence of the nano-scale silica were quantified. Inspection of the failure modes revealed that the existence of colloidal silica promotes crack propagation along a more tortuous path within the interphase that results in progressive failure and contributes to increased energy dissipation.     

Effects of the marine environment on the interfacial fracture toughness of PVC core sandwich composites

An experimental study was undertaken to investigate the facesheet/core interfacial fracture toughness of E-Glass/Vinylester facesheet, closed-cell polyvinyl chloride (PVC) core, sandwich composites. To determine the effects of a marine environment (temperature and sea-water) on conditioned specimens with a crack present, an interfacial crack was induced prior, as well as subsequent to, 5000 h of elevated temperature (80 °C), elevated temperature and moisture (80 °C, 90%+ relative humidity), and sea-water (submersed) conditioning. The interfacial fracture toughness from room temperature double cantilever beam tests for each environmental condition was then compared using the critical strain energy release rate, G_C. The G_C was reduced considerably (greater than 50%) in specimens submerged in sea-water, and significantly (approximately 90%) due to 5000 h of the ‘hot/wet’ and hot/dry exposure. Results showed that elevated temperature exposure contributes greatest to the PVC core degradation, whereas sea-water exposure mostly degrades the facesheet/core interface. Exposure to elevated temperatures, along with inducing cracks between the facesheet and a PVC core degraded by elevated temperature exposure, appear to be the most detrimental to interfacial fracture toughness.