4.7 Article

Effect of fibre straightness and sizing in carbon fibre reinforced powder epoxy composites

Journal

Publisher

ELSEVIER SCI LTD
DOI: 10.1016/j.compositesa.2018.04.013

Keywords

Carbon fibre; Powder epoxy; Mechanical properties; Interface bonding

Funding

  1. MARINCOMP
  2. Novel Composite Materials and Processes for Marine Renewable Energy
  3. EU FP7-People
  4. Industry Academia Partnerships and Pathways (IAPP) [612531]
  5. POWDERBLADE
  6. Commercialisation of Advanced Composite Material Technology: Carbon-Glass Hybrid in Powder Epoxy for Large Wind Turbine Blades [730747]
  7. EPSRC [EP/P029922/1] Funding Source: UKRI

Ask authors/readers for more resources

Carbon fibres with three different sizing agents were used to manufacture unidirectional composites based on powder epoxy resin. A specially designed tensioning apparatus was adopted to apply tension on fibres during the thermal curing cycle, in order to achieve an enhancement of fibre straightness. Chemical composition and surface morphologies of the carbon fibres were extensively characterised. The composites were evaluated using tensile, flexural and interlaminar shear strength tests, and mechanical performance measured based on fibre orientation, fracture modes and interfacial properties. The results demonstrated that composites processed with fibres under tension resulted in an increased unidirectional character in connection with the different amounts of sizing. Flexural and interlaminar testing of the laminates, in addition to Scanning Electron Microscopy and Dynamic Mechanical Thermal Analyses, revealed interfacial adhesion differences, emphasizing the importance of the adequate combination of the polymeric matrix and the type of reinforcement to the structural integrity of composite.

Authors

I am an author on this paper
Click your name to claim this paper and add it to your profile.

Reviews

Primary Rating

4.7
Not enough ratings

Secondary Ratings

Novelty
-
Significance
-
Scientific rigor
-
Rate this paper

Recommended

Article Engineering, Multidisciplinary

Effect of glass fibre sizing on the interfacial properties of composites produced using in-situ polymerised Polyamide-6 transfer moulding

James J. Murray, Ankur Bajpai, James Quinn, Jake McClements, Klaus Gleich, Edward D. McCarthy, Conchur M. O. Bradiagh

Summary: This study investigates the fibre-matrix interfacial properties of glass-fibre/polyamide-6 composites produced by thermoplastic resin transfer moulding. The results show that the use of a novel reactive fibre sizing improves the adhesion between fibres and matrix, as well as the fracture toughness of the composites.

COMPOSITES PART B-ENGINEERING (2022)

Article Materials Science, Multidisciplinary

Mechanical characterisation of pneumatically-spliced carbon fibre yarns as reinforcements for polymer composites

James R. Davidson, James A. Quinn, Claudia Rothmann, Ankur Bajpai, Colin Robert, Conchur M. O. Bradaigh, Edward D. McCarthy

Summary: The study investigates the mechanical response of pneumatically-spliced carbon fiber yarns as a potential reinforcing material for polymer composites. Results show that pneumatic splicing provides a high strength and sustainable solution for reinforcing polymers with discontinuous carbon fiber yarns, which can be used in weaving, braiding, non-crimp fabrics, or 3D printing applications. Further research on quasi-continuous yarns remanufactured by splicing waste fibers could offer a novel material for various applications.

MATERIALS & DESIGN (2022)

Article Engineering, Multidisciplinary

3D printing and epoxy-infusion treatment of curved continuous carbon fibre reinforced dual-polymer composites

Haoqi Zhang, Jiang Wu, Colin Robert, Conchur M. O. Bradaigh, Dongmin Yang

Summary: A manufacturing technique combining 3D printing and epoxy infusion treatment was developed to fabricate curved continuous carbon fibre reinforced composites. The stiffness and strength of the printed composites were significantly increased compared to traditional thermoplastic-only composites. The study also showed that placing continuous carbon fibres along the principal stress trajectories greatly improved the failure strength and fracture toughness of the composites.

COMPOSITES PART B-ENGINEERING (2022)

Article Materials Science, Composites

Influence of Line Processing Parameters on Properties of Carbon Fibre Epoxy Towpreg

Murat Celik, Thomas Noble, Frank Jorge, Rongqing Jian, Conchur M. O. Bradaigh, Colin Robert

Summary: This paper investigates the performance of low-cost unidirectional carbon fibre towpregs in terms of line production speed and fibre volume fraction. The results show that adjusting the production speed allows for different fibre volume fractions to be achieved, resulting in composites with varying mechanical properties. Additionally, fibre straightness plays a key role in the mechanical performance of the composites.

JOURNAL OF COMPOSITES SCIENCE (2022)

Article Engineering, Manufacturing

Crystallisation behaviour and morphological studies of PEKK and carbon fibre/PEKK composites

Helena Perez-Martin, Paul Mackenzie, Alex Baidak, Conchur M. O. Bradaigh, Dipa Ray

Summary: This study evaluated the crystallization behavior of carbon fiber/poly(etherketoneketone) (CF/PEKK) composites and found that different thermal cycles affected the crystallinity, with the inclusion of carbon fibers increasing the proportion of secondary crystallization and slowing down the crystallization kinetics. The optimal isothermal hold temperatures during cooling for CF/PEKK were estimated to be in the range of 220-260 ℃.

COMPOSITES PART A-APPLIED SCIENCE AND MANUFACTURING (2022)

Article Materials Science, Composites

Contact resistance heating of unidirectional carbon fibre tows in a powder-epoxy towpregging line

Murat Celik, Thomas Noble, Abdul Haseeb, James Maguire, Colin Robert, Conchur M. O. Bradaigh

Summary: Contact resistances are important in Joule heating systems. Measuring the contact resistances between metal roller electrodes and carbon fiber tows provides a better understanding and improves the accuracy of the heating process. The study shows that contact resistances in the towpregging line are significant and contact resistance heating changes the heating profile.

PLASTICS RUBBER AND COMPOSITES (2022)

Article Materials Science, Composites

3D printing of continuous carbon fibre reinforced powder-based epoxy composites

Haoqi Zhang, Ka Zhang, Aonan Li, Lei Wan, Colin Robert, Conchur M. O. Bradaigh, Dongmin Yang

Summary: This paper presents an experimental study on 3D printing of continuous carbon fibre reinforced thermoset epoxy composites. The study shows that the produced composites have high tensile strength and modulus in the fibre direction due to the good wettability of epoxy and high fibre volume fraction. The study also demonstrates the design freedom of the produced filaments for complex geometries and the improved strength of composites with designed stress-lines fibre paths.

COMPOSITES COMMUNICATIONS (2022)

Article Engineering, Manufacturing

Numerical and experimental investigation of Joule heating in a carbon fibre powder epoxy towpregging line

Murat Celik, James M. Maguire, Thomas Noble, Colin Robert, Conchur M. O. Bradaigh

Summary: This study focused on improving the towpregging process by analysing the heating characteristics of a towpregging line that uses Joule heating. A heat transfer model was developed to identify the relationship between processing parameters and heating of the carbon fibre tows. Results showed that Joule heating provides efficient heating with low power consumption. It was also found that slower speeds might yield more consistent quality, and it is possible to increase production rate without compromising quality by altering key process parameters.

COMPOSITES PART A-APPLIED SCIENCE AND MANUFACTURING (2023)

Article Engineering, Multidisciplinary

Thermal reshaping as a route for reuse of end-of-life glass fibre-reinforced acrylic composites

Winifred Obande, Danijela Stankovic, Ankur Bajpai, Machar Devine, Christian Wurzer, Anna Lykkeberg, Jennifer A. Garden, Conchur M. O. Bradaigh, Dipa Ray

Summary: Thermal reshaping was used to simulate the end-of-life reuse of liquid-resin-infused thermoplastic acrylic composite laminates, and its effects on mechanical performance and microstructure were studied. Reprocessed laminates showed up to 13% higher flexural strengths compared to the original references. This study provides insights for the practical reuse and re-application of sustainable composites in a circular economy.

COMPOSITES PART B-ENGINEERING (2023)

Article Engineering, Multidisciplinary

Seawater ageing of thermoplastic acrylic hybrid matrix composites for marine applications

Machar Devine, Ankur Bajpai, Winifred Obande, Conchur M. O. Bradaigh, Dipa Ray

Summary: The increasing use of polymer composite materials requires the development of recyclable alternatives or new recycling techniques. One promising recyclable alternative is the room temperature infusible acrylic resins commercially known as Elium & REG;. This study investigates the long-term immersion of these materials in seawater and compares their mechanical properties and fracture behavior to traditional epoxy composites.

COMPOSITES PART B-ENGINEERING (2023)

Article Materials Science, Composites

Effects of thermal process conditions on crystallinity and mechanical properties in material extrusion additive manufacturing of discontinuous carbon fibre reinforced polyphenylene sulphide composites

Yahui Lyu, Jiang Wu, Haoqi Zhang, Conchur M. O. Bradaigh, Dongmin Yang

Summary: This study investigates the thermal behaviour of discontinuous carbon fibre reinforced polyphenylene sulphide (CF/PPS), additively manufactured by material extrusion. The effects of thermal process conditions on the degree of crystallinity, oxidation crosslinking and mechanical properties of CF/PPS are studied from filament fabrication to annealing treatment. By optimizing the screw extrusion parameters, the thermal analysis of the fabricated filaments is performed. The influence of crosslinking reactions on crystallinity process and mechanical properties is determined by investigating the printing conditions.

JOURNAL OF COMPOSITE MATERIALS (2023)

Article Materials Science, Multidisciplinary

Microstructural and micromechanical property characterisation of CF/ PEKK composites using nanoindentation

Helena Perez-Martin, Paul Mackenzie, Alex Baidak, Conchur M. O. Bradaigh, Dipa Ray

Summary: The present work focuses on characterizing the micromechanical properties of CF/PEKK composites with different crystallinity levels and morphologies. The study demonstrates that compression-moulded laminates have a superior polymer matrix compared to ATP laminates. Nanoindentation testing reveals a transition from the fiber to the matrix bulk in all samples. The study of micromechanical properties provides insights into the impact of manufacturing conditions on the composite's macro performance.

MATERIALS & DESIGN (2023)

Article Engineering, Manufacturing

Characterising the shear resistance of a unidirectional non-crimp glass fabric using modified picture frame and uniaxial bias extension test methods

K. D. H. N. Kahavita, E. D. McCarthy, M. Zhang, C. M. O. Bradaigh, P. Harrison

Summary: This research examines the forming behavior of a unidirectional non-crimp fabric (UD-NCF) made of polyamide stitches with a tricot-chain stitching pattern. The absence of stabilizing tows in this fabric allows for transverse extension of the stitch under certain loading conditions. The in-plane shear behavior is investigated using both standard picture frame tests and uniaxial bias extension tests, with different test methods yielding different results.

INTERNATIONAL JOURNAL OF MATERIAL FORMING (2023)

Article Polymer Science

Advanced Ultrasonic Inspection of Thick-Section Composite Structures for In-Field Asset Maintenance

James A. Quinn, James R. Davidson, Ankur Bajpai, Conchur M. O. Bradaigh, Edward D. McCarthy

Summary: This investigation focuses on the inspection capabilities of in-field advanced ultrasound detection for ultra-thick glass fibre-reinforced polyester composites. Delamination flaws were created at calibrated depths using custom moulding techniques. The study utilized the full matrix capture technique with an on-board total focusing method and a 0.5 MHz linear array probe to detect flaws. The results demonstrate an inverse relationship between the ability to find delaminations and plate thicknesses, with successful inspections up to 74 mm.

POLYMERS (2023)

Article Materials Science, Multidisciplinary

Effect of crystallinity and morphology on the mechanical properties of CF/ PEKK composites manufactured under compression moulding and automated tape placement

Helena Perez-Martin, Stefan Buchalik-Bopp, Barbara E. Guettler, Paul Mackenzie, Alex Baidak, Conchur M. O. Bradaigh, Dipa Ray

Summary: The present study aimed to investigate the impact of crystallisation morphology and kinetics on the matrix-dominated properties of CF/PEKK composites, factors that have been minimally studied together in existing literature. Different processing routes, including compression-moulding and automated tape placement (ATP), were employed to examine their effects on void content, crystallinity development, morphology, and mechanical performance. Results showed that compression-moulded laminates achieved similar levels of consolidation and crystallinity under different isothermal crystallisation conditions, while the spherulitic development varied significantly. The performance of ATP laminates was lower due to higher void content and lower crystallinity, indicating the need for a comprehensive understanding of the correlation between processing conditions and crystalline structure development in PEKK.

MATERIALS TODAY COMMUNICATIONS (2023)

Article Engineering, Manufacturing

Characterization of tool-ply friction behavior for treated jute/PLA biocomposite prepregs in thermoforming

Wenwu Zhang, Helezi Zhou, Bin Huang, Huamin Zhou, Xiongqi Peng

Summary: This paper investigates the tool-ply friction behavior of jute/PLA biocomposites in thermoforming. A pull-through friction testing device was developed to characterize the tool-ply friction behavior of jute/PLA prepreg at elevated temperature. The effects of alkali treatment, fiber orientation, normal force, and slipping velocity were studied, and a quantitative definition of tool-ply friction behavior was achieved. The results indicate a strong relationship between tool-ply friction behavior and woven and fiber structures, indicating hydrodynamic lubrication.

COMPOSITES PART A-APPLIED SCIENCE AND MANUFACTURING (2024)

Article Engineering, Manufacturing

Experimental characterization of compression failure mechanism initiation and growth in notched carbon fiber reinforced composite specimens

Stephen Clay, Wesley Ault, Alex Faupel, Caglar Oskay, Philip Knoth, Noam N. Y. Shemesh, Rami Haj-Ali, Uri Breiman, Ido Meshi, Ofir Shor

Summary: This paper presents an experimental investigation on the compression failure mechanisms of laminated carbon fiber reinforced composites under non-standard quasi-static loading. The results demonstrate the presence of interior kink bands, surface ply splitting, and delaminations, with each failure mechanism associated with different stress levels.

COMPOSITES PART A-APPLIED SCIENCE AND MANUFACTURING (2024)

Article Engineering, Manufacturing

Improved pyroelectric performances of functionally graded graphene nanoplatelet reinforced polyvinylidene fluoride composites: Experiment and modelling

Bowen Zeng, Jinlong Yang, Zhi Ni, Yucheng Fan, Ziyan Hang, Chuang Feng

Summary: This study successfully improved the pyroelectric properties of PVDF films by preparing functionally graded graphene nanoplatelet (FG-GNP) reinforced PVDF composite films. The increase in the number of layers and the concentration of GNP near the surface of the composite film were found to enhance the pyroelectric properties and temperature stability.

COMPOSITES PART A-APPLIED SCIENCE AND MANUFACTURING (2024)

Article Engineering, Manufacturing

Investigation of nanocomposite system with long-chain phosphorus-containing intercalator-modified montmorillonite nanosheets

Shenghe Zhang, Fukai Chu, Weizhao Hu, Bibo Wang, Richard K. K. Yuen, Yuan Hu

Summary: This study improves the flame retardancy and mechanical properties of PBAT by synthesizing a phosphorus-containing intercalator and mixing it into the PBAT matrix.

COMPOSITES PART A-APPLIED SCIENCE AND MANUFACTURING (2024)

Article Engineering, Manufacturing

Suppression of compression induced delamination in tapered laminated composites using a ply scarfing method

Tharan Gordon, Michael R. Wisnom, Byung Chul Kim

Summary: Thickness tapering is a common strategy for efficient and lightweight composite structures, but it can introduce delamination sites. This study investigated the use of ply scarfing method to improve the compressive failure stress of tapered laminates made from thick unidirectional non-crimp fabrics. The results showed that ply scarfing suppressed delamination and increased the failure stress by 60%.

COMPOSITES PART A-APPLIED SCIENCE AND MANUFACTURING (2024)

Article Engineering, Manufacturing

Pre-compositing polyetherketoneketone with short-cut carbon fibers into advanced powder materials toward composites with fully-adhered interfaces

Xin Wang, Yiting Qu, Junlei Bai, Fujun Xu, Bin Ding, Xiaohua Zhang

Summary: A solution-based strategy is proposed to achieve a strong bond between fibers and matrix in powder materials, resulting in improved mechanical properties, thermal conductivity, and fracture strain of the composites. The method also offers advantages such as enhanced powder flowability and thermal stability.

COMPOSITES PART A-APPLIED SCIENCE AND MANUFACTURING (2024)

Article Engineering, Manufacturing

Shape-memory polyurethane elastomer originated from waste PET plastic and their composites with carbon nanotube for sensitive and stretchable strain sensor

Xing Zhou, Guosheng Wang, Dexiang Li, Qi Wang, Keming Zhu, Yaya Hao, Yueyang Xu, Neng Li

Summary: This study successfully synthesized polyurethane elastomer by using degraded products from waste PET, and fabricated composites with carbon nanotubes for strain sensors. The composites showed good mechanical and durability performance, indicating a potential method for recycling waste PET into valuable and functional materials.

COMPOSITES PART A-APPLIED SCIENCE AND MANUFACTURING (2024)

Article Engineering, Manufacturing

Facilely fabricated Janus polymer film for actuator and self-powered sensor

Fei Peng, Tingting Shan, Rongrui Chen, Jiulong Shi, Di Liu, Guoqiang Zheng, Chaojun Gao, Kun Dai, Chuntai Liu, Changyu Shen

Summary: Janus polymer films with distinct surface performance and potential applications were successfully prepared by vacuum-assisted hot-compressing method and spray coating. These films exhibit decent actuation performance and rapid selfpowered sensing property, and can be used for real-time acetone monitoring system.

COMPOSITES PART A-APPLIED SCIENCE AND MANUFACTURING (2024)

Article Engineering, Manufacturing

Enhanced thermal conductivity of phase change composites with novel binary graphite networks

Biao Cheng, Huafeng Quan, Yuefeng Zhang, Dong Huang, Tongqi Li, Chong Ye, Xingming Zhou, Zhen Fan, Yafang Zhang, Ting Ouyang, Fei Han, Hongbo Liu, Jinshui Liu

Summary: In this study, a binary graphite network was constructed to improve the thermal conductivity and control the formation of micrometer-scale open pores in phase change composites. The developed composites showed a high thermal conductivity and phase change enthalpy, making them promising for thermal control in space optical-mechanical systems and other critical aerospace components.

COMPOSITES PART A-APPLIED SCIENCE AND MANUFACTURING (2024)

Article Engineering, Manufacturing

An effective micro-arc oxidation (MAO) treatment on aluminum alloy for stronger bonding joint with carbon fiber composites

Shihao Zuo, Fei Cheng, Guangming Yang, Jiangzhou Li, Yongjun Deng, Guangjun Gou, Xuejun Cui, Yunsen Hu, Xiaozhi Hu

Summary: Micro-arc oxidation (MAO) treatment was used to modify aluminum (Al) alloys in order to improve bond strength with carbon fiber reinforced polymer (CFRP). The treatment successfully created a porous surface with better hardness, roughness, and wetting, and introduced resin pre-coating (RPC) and carbon nanotube (CNT) fiber bridging to improve the bonding interface. The combined treatments significantly increased the bond strength by up to 156.1%, indicating the feasibility of MAO as an alternative method for manufacturing high-performance Al-CFRP composites in industrial production.

COMPOSITES PART A-APPLIED SCIENCE AND MANUFACTURING (2024)

Article Engineering, Manufacturing

Effects of accelerated curing in thermoplastic particle interleaf epoxy laminates

James Kratz, Christophe Paris, Karolina Gaska, Vincent Maes, Ivana Partridge, Philippe Olivier

Summary: Faster heating rates and higher process temperatures can reduce the total process time while achieving the same degree-of-cure. Thermal analysis shows that thermoplastic interleaf particles melt at the recommended curing temperature. A short dwell at a lower temperature can prevent the mixing of thermoplastic particles and thermoset pre-polymer.

COMPOSITES PART A-APPLIED SCIENCE AND MANUFACTURING (2024)

Article Engineering, Manufacturing

Resistance-welded thermoset composites: A Bayesian approach to process optimisation for improved fracture toughness

Thomas Maierhofer, Evripides G. Loukaides, Craig Carr, Chiara Bisagni, Richard Butler

Summary: Joining thermoset composites via resistance welding provides an efficient method for aerospace structures with benefits such as high-volume manufacturing and simplified surface preparation. The influence of welding parameters on joint performance is assessed using Mode I fracture toughness testing. A Bayesian approach is employed to select high-performance parameters.

COMPOSITES PART A-APPLIED SCIENCE AND MANUFACTURING (2024)

Article Engineering, Manufacturing

High-performance chlorinated polyvinyl chloride/polyurea nanocomposite foam with excellent solvent resistance, flame-triggered shape memory effect and its upcycling

Jiangan You, Ling Cai, Ronghua Yu, Haiping Xing, Jian Xue, Ying Li, Zhiwei Jiang, Dongmei Cui, Tao Tang

Summary: In response to the global environmental pollution crisis caused by waste plastics, recyclable design is an effective solution. A CPVC/PUA nanocomposite foam was developed using the plasticizing-foaming-reinforcing strategy, combined with catalytic carbonization. The foam exhibited high expansion ratio, robustness, solvent resistance, flame-triggered shape memory effect, and ablation resistance. The foam could be directly upcycled into functional carbon foam with attractive electromagnetic interference shielding performance.

COMPOSITES PART A-APPLIED SCIENCE AND MANUFACTURING (2024)

Article Engineering, Manufacturing

Flexible multiwalled carbon nanotubes/cellulose nanofibers membrane with rapid temperature increasing induced by interface strengthening

Siyao Chen, Zhiyu Chen, Yangling Ou, Junwei Lyu, Junning Li, Xiangyang Liu, Yang Liu

Summary: In this study, we demonstrated the significant effect of composite interface on temperature increase in electrical heaters. By selectively fluorinating the outer walls of carbon nanotubes and compositing them with cellulose nanofibers, improved interfacial phonon diffusion was achieved, leading to a higher temperature increase rate.

COMPOSITES PART A-APPLIED SCIENCE AND MANUFACTURING (2024)

Article Engineering, Manufacturing

Effect of atomic oxygen exposure on polybenzoxazine/POSS nanocomposites for space applications

Yanjun He, Agnieszka Suliga, Alex Brinkmeyer, Mark Schenk, Ian Hamerton

Summary: A new thermoset resin system based on a polybenzoxazine blend showed good performance under high ATOX irradiation. It reduced erosion yield by forming a silicon-rich surface layer and improved the mechanical properties of CFRP laminates.

COMPOSITES PART A-APPLIED SCIENCE AND MANUFACTURING (2024)