Composite materials based on silk proteins

A number of animals have evolved to produce silk-based composite materials for a variety of task-specific applications. The review initially focuses on the composite structure of silk fibers produced naturally by silkworms and spiders, followed by the preparation and applications of man-made composite materials (including fibers, films, foams, gels and particulates) incorporating silk proteins in combination with other polymers (both natural and synthetic) and/or inorganic particles. 

Electrical and Rheological Percolation of PMMA/MWCNT Nanocomposites as a Function of CNT Geometry and Functionality

The ability of carbon nanotubes (CNTs) to reinforce and enhance the electrical conductivity of polymer matrices is a function of both the aspect ratio and surface chemistry of the CNTs. Hitherto, due to the variability in MWCNT synthesis methods it has not been possible to study the effect of MWCNT aspect ratio and functionality on polymer composite properties. This paper was the first to report the correlation between MWCNT aspect ratio and functionality on the formation of electrical and rheological percolated networks. Furthermore, the fundamental ballistic conductance of MWCNTs made using arc discharge and chemical vapour deposition techniques was reported.

Improved model for interfacial stresses accounting for the effect of shear deformation in plated beams

A significant increase in strength and performance of reinforced concrete, timber and metal beams may be achieved by adhesively bonding a fibre reinforced polymer composite, or metallic such as steel plate to the tension face of a beam. One of the major failure modes in these plated beams is the debonding of the plate from the original beam in a brittle manner. This is commonly attributed to the interfacial stresses between the adherends whose quantification has led to the development of many analytical solutions over the last two decades. The adherends are subjected to axial, bending and shear deformations. However, most analytical solutions have neglected the effect of shear deformation in adherends. Few solutions consider this effect approximately but are limited to one or two specific loading conditions. This paper presents a more rigorous solution for interfacial stresses in plated beams under an arbitrary loading with the shear deformation of the adherends duly considered in closed form using Timoshenko’s beam theory. The solution is general to linear elastic analysis of prismatic beams of arbitrary cross section under arbitrary loading with a plate of any thickness bonded either symmetrically or asymmetrically with respect to the span of the beam.

Glass fibre-reinforced polyethylene composites in rotational moulding

Fibre-reinforced mouldings are of growing interest to the rotational moulding industry due to their outstanding price performance ratio. However, a particular problem that arises when using reinforcements in this process is that the process is low shear and good mixing of resin and reinforcement is not optimum under those conditions. There is also a problem of the larger/heavier reinforcing agents segregating out of the powder to lay up on the inner part surface. In this paper we report on studies to incorporate, short glass fibres into rotationally moulded parts. Four different approaches were investigated; direct addition of fibre in between two powder shots, addition of a layer of pre-compounded polyethylene-glass fibre pellets between two powder shots, addition of a layer of pre-compounded polyethylene-glass fibre powder between two powder shots and a single layer of glass-reinforced, pre-compounded powder. Results indicate that pre-compounding is necessary to gain performance enhancement and the single layer part made from glass-reinforced, pre-compounded powder exhibited the highest tensile and flexural modulus.

Development of composite tissue scaffolds containing naturally sourced mircoporous hydroxyapatite

The aims of this work were to investigate the conversion of a marine alga into hydroxyapatite (HA), and furthermore to design a composite bone tissue engineering scaffold comprising the synthesised HA within a porous bioresorbable polymer. The marine alga Phymatolithon calcareum, which exhibits a calcium carbonate honeycomb structure, with a natural architecture of interconnecting permeable pores (microporosity 4-11 mu m), provided the initial raw material for this study. The objective was to convert the alga into hydroxyapatite while maintaining its porous morphology using a sequential pyrolysis and chemical synthesis processes. Semi-quantitative XRD analysis of the post-hydrothermal material (pyrolised at 700-750 degrees C), indicated that the calcium phosphate (CaP) ceramic most likely consisted of a calcium carbonate macroporous lattice, with hydroxyapatite crystals on the surface of the macropores. Cell visibility (cytotoxicity) investigations of osteogenic cells were conducted on the CaP ceramic (i.e., the material post-hydrothermal analysis) which was found to be non-cytotoxic and displayed good biocompatibility when seeded with MG63 cells. Furthermore, a hot press scaffold fabrication technique was developed to produce a composite scaffold of CaP (derived from the marine alga) in a polycaprolactone (PCL) matrix. A salt leaching technique was further explored to introduce macroporosity to the structure (50-200 mu m). Analysis indicated that the scaffold contained both micro/macroporosity and mechanical strength, considered necessary for bone tissue engineering applications. (C) 2008 Published by Elsevier B.V.

Fatigue Damage of Composite Structures Applying a Micromechanical Approach

Fatigue damage calculations of unidirectional polymer composites is presented applying micromechanics theory. An orthotropic micromechanical damage model is integrated with an isotropic fatigue evolution model to predict the micromechanical fatigue damage of the composite structure. The orthotropic micromechanical damage model is used to predict the orthotropic damage evolution within a single cycle. The isotropic fatigue model is used to predict the magnitude of fatigue damage accumulated as a function of the number of cycles. The advantage of using this approach is the cheap determination of model parameters since the orthotropic damage model parameters can be determined using available data from quasi-static loading tests. Decomposition of the state variables down to the constituent scale is accomplished by micromechanics theory. Phenomenological damage evolution models are then postulated for each constituent and for interphase among them. Comparison between model predictions and experimental data is presented.

A micromechanics approach for damage modeling of polymer matrix composites

A new model for damage evolution in polymer matrix composites is presented. The model is based on a combination of two constituent-level models and an interphase model. This approach reduces the number of empirical parameters since the two constituent- level models are formulated for isotropic materials, namely fiber and matrix. Decomposition of the state variables down to the micro-scale is accomplished by micromechanics. Phenomenological damage evolution models are then postulated for each constituent. Determination of material parameters is made from available experimental data. The required experimental data can be obtained with standard tests. Comparison between model predictions and additional experimental data is presented.

A micro-mechanics damage approach for fatigue of composite materials

A new model for fatigue damage evolution of polymer matrix composites (PMC) is presented. The model is based on a combination of an orthotropic damage model and an isotropic fatigue evolution model. The orthotropic damage model is used to predict the orthotropic damage evolution within a single cycle. The isotropic fatigue model is used to predict the magnitude of fatigue damage accumulated as a function of the number of cycles. This approach facilitates the determination of model parameters since the orthotropic damage model parameters can be determined from available data from quasi-static-loading tests. Then, limited amount of fatigue data is needed to adjust the fatigue evolution model. The combination of these two models provides a compromise between efficiency and accuracy. Decomposition of the state variables down to the constituent scale is accomplished by micro-mechanics. Phenomenological damage evolution models are then postulated for each constituent and for the micro-structural interaction among them. Model parameters are determined from available experimental data. Comparison between model predictions and additional experimental data is presented.

Three dimensional morphology and compressive behaviour of sintered biodegradable composite scaffolds

Porous poly-L-lactide acid (PLA) scaffolds are prepared using polymer sintering and porogen leaching method. Different weight fractions of the Hydroxyapatite (HA) are added to the PLA to control the acidity and degradation rate. The three dimensional morphology and surface porosity are tested using micro CT, optical microscopy and scanning electron microscopy (SEM). Results indicate that the surface porosity does not change by addition of HA. The micro Ct examinations show slight decrease in the pore size and increase in wall thickness accompanied with reduced anisotropy for the scaffolds containing HA. SEM micrographs show detectable interconnected pores for the scaffold with pure PLA. Addition of the HA results in agglomeration of the HA which blocks some of the pores. Compression tests of the scaffold identify three stages in the stress-strain curve. The addition of HA adversely affects the modulus of the scaffold at the first stage, but this was reversed for the second and third stages of the compression. The results of these tests are compared with the cellular material model. The manufactured scaffold have acceptable properties for a scaffold, however improvement to the mixing of the phases of PLA and HA is required to achieve better integrity of the composite scaffolds.

POST-TENSIONING OF TIMBER BEAMS WITH BASALT FIBRE REINFORCED POLYMER

Improvements in the structural performance of glulam timber beams by the inclusion of reinforcing materials can improve both the service performance and ultimate capacity. In recent years research focusing on the addition of fibre reinforced polymers to strengthen members has yielded positive results. However, the FRP material is still a relatively expensive material and its full potential has not been realised in combination with structural timber. This paper describes a series of four-point bending tests that were conducted, under service and ultimate loads, on post-tensioned glulam timber beams where the reinforcing tendon used was 12 mm diameter Basalt Fibre Reinforced Polymer (BFRP). The research was designed to evaluate the additional benefits of including an active type of reinforcement, by post-tensioning the BFRP tendon, as opposed to the passive approach of simply reinforcing the timber beam.
From the laboratory investigations, it was established that there was a 16% increase in load carrying capacity, in addition to a 14% reduction in deflection under service loads when members containing the post-tensioned BFRP composite are compared with control timber specimens. Additionally a more favourable ductile failure mode was witnessed compared to the brittle failure of an unreinforced timber beam. The results support the assumption that by initially stressing the embedded FRP tendon the structural benefits experienced by the timber member increase in a number of ways, indicating that there is significant scope for this approach in practical applications.

Development and evaluation of a novel integrated anti-icing/de-icing technology for carbon fibre composite aerostructures using an electro-conductive textile

The preliminary evaluation is described of a new electro-thermal anti-icing/de-icing device for carbon fibre composite aerostructures. The heating element is an electro-conductive carbon-based textile (ECT) by Gorix. Electrical shorting between the structural carbon fibres and the ECT was mitigated by incorporating an insulating layer formed of glass fibre plies or a polymer film. A laboratory-based anti-icing and de-icing test program demonstrated that the film-insulated devices yielded better performance than the glssass fibre insulated ones. The heating capability after impact damage was maintained as long as the ECT fabric was not breached to the extent of causing electrical shorting. A modified structural scarf repair was shown to restore the heating capacity of a damaged specimen.

Characterisation of Bioresorbable Composite Performance for Validation of New On-Line Process Monitoring Technology

There is an increasing interest in the biomedical field to create implantable medical devices to provide a temporary mechanical function for use inside the human body. In many of these applications bioresorbable polymer composites using PLLA with β-TCP , are increasingly being used due to their biocompatability, biodegradability and mechanical strength.1,3 These medical devices can be manufactured using conventional plastics processing methods such as injection moulding and extrusion, however there is great need to understand and control the process due to a lack of knowledge on the influence of processing on material properties. With the addition of biocompatible additives there is also a requirement to be able to predict the quality and level of dispersion within the polymer matrix. On-line UV-Vis spectroscopy has been shown to monitor the quality of fillers in polymers. This can eliminate time consuming and costly post-process evaluation of additive dispersion. The aim of this work was to identify process and performance relationships of PLLA/β-TCP composites with respect to melt-extrusion conditions. This is part of a wider study into on-line process monitoring of bioresorbable polymers as used in the medical industry.
These results show that final properties of the PLLA/ β-TCP composite are highly influenced by the particle size and loading. UV-Vis spectroscopy can be used on-line to monitor the final product and this can be utilised as a valuable tool for quality control in an application where consistent performance is of paramount importance.

Modelling the nonlinear behaviour and fracture process of AS4/PEKK thermoplastic composite under shear loading

The accurate determination of non-linear shear behaviour and fracture toughness of continuous carbon-fibre/polymer composites remains a considerable challenge. These measurements are often necessary to generate material parameters for advanced computational damage models. In particular, there is a dearth of detailed shear fracture toughness characterisation for thermoplastic composites which are increasingly generating renewed interest within the aerospace and automotive sectors. In this work, carbon fibre (AS4)/ thermoplastic Polyetherketoneketone (PEKK) composite V-notched cross-ply specimens were manufactured to investigate their non-linear response under pure shear loading. Both monotonic and cyclic loading were applied to study the shear modulus degradation and progressive failure. For the first time in the reported literature, we use the essential work of fracture approach to measure the shear fracture toughness of continuous fibre reinforced composite laminates. Excellent geometric similarity in the load-displacement curves was observed for ligament-scaled specimens. The laminate fracture toughness was determined by linear regression, of the specific work of fracture values, to zero ligament thickness, and verified with computational models. The matrix intralaminar fracture toughness (ply level fracture toughness), associated with shear loading was determined by the area method. This paper also details the numerical implementation of a new three-dimensional phenomenological model for carbon fibre thermoplastic composites using the measured values, which is able to accurately represent the full non-linear mechanical response and fracture process. The constitutive model includes a new non-linear shear profile, shear modulus degradation and load reversal. It is combined with a smeared crack model for representing ply-level damage initiation and propagation. The model is shown to accurately predict the constitutive response in terms of permanent plastic strain, degraded modulus as well as load reversal. Predictions are also shown to compare favourably with the evolution of damage leading to final fracture.