One-step amino-functionalization of milled carbon fibre for enhancement of thermo-physical properties of epoxy composites

Development of new chemical approaches for preparation of engineered carbon-based fillers is critical for high-performance applications. Herein, an efficient method for covalent functionalization of polyacrylonitrile-based carbon fibre through azo radical addition under mild condition is demonstrated. In this way, isobutyronitrile radicals in situ produced from thermal decomposition of 2,2′-azobisisobutyronitrile (AIBN), were covalently grafted on milled carbon fibre (MCF) surface, assisted by microwave irradiation, as evidenced by FTIR, Raman, and TGA analysis. The grafted isobutyronitriles on MCF surface (n-MCF) were applied for further MCF amino-functionalization (a-MCF) via nucleophilic reaction of an amine-rich compound. Then, both pure MCF and a-MCF were incorporated into epoxy matrix; and its curing process and thermo-physical properties were investigated using DSC, rheometry, DMA, TGA, and flexural analysis. The Tg and flexural strength of epoxy/a-MCF composites, compared to epoxy/MCF, increased by ∼3.5% and ∼10.2%, resulting from good adhesion between a-MCF and epoxy matrix which confirmed by SEM observations.

Interfacial characterization and reinforcing mechanism of novel carbon nanotube – carbon fibre hybrid composites

Carbon nanotube (CNT) deposition onto carbon fibre resulting in hybrid surface structures with various morphologies were successfully carried out using electrospray technique. In terms of tensile testing and Weibull analysis this process did not degrade fibre mechanical properties. When incorporated into composites, the interfacial shear strength (IFSS), as measured by single fibre fragmentation testing, increased by up to 124%. Experimental work was carried out to develop a deeper understanding of the interfacial reinforcing mechanism. Contact angle measurements demonstrated that the CNT deposition resulted in good wettability by the resin. Significant increases in roughness, friction and surface area were also found after CNT deposition, especially for the sample prepared using the parameter of 20 kV/10 cm at 100 °C. Surface energy analysis revealed that an increase in the dispersive surface energy due to the CNTs likely contributed to the improvement of interaction between fibre and matrix. Fractographic analysis revealed that the length of fibre pull-out and the size of cracks between the fibre and matrix were markedly decreased in the hybrid CNT surface structure, indicating that the stress transfer and interfacial shear strength have been improved. Finally, the potential for further improvement in interfacial composite properties by this approach was assessed.

Interface slip control for CFRP-concrete composite beams

Carbon fibre reinforced polymer (CFRP) has been used frequently to retrofit concrete structures. Strengthening efficiency is related to the CFRP application process and the characteristics of the bonding agent. In this paper the mechanism of interface shear behaviour in CFRP to concrete beams is discussed considering previous test observations and mathematical models. This paper then discusses the consequences of introducing interface slip which reduces the integrity of the composite section, however improve ductility and delay debonding failure. The paper suggests that using softer bonding agent as well as setting limits on the interface slip could ensure acceptable serviceability and ductile behaviour.

Effect of the manufacturing process on the interlaminar fracture toughness of 2/2 twill weave fabric carbon/epoxy composites

A 2/2 twill weave fabric carbon fibre reinforced epoxy matrix composite MTM56/CF0300 was used to investigate the effect of different manufacturing processes on the interlaminar fracture toughness. Double cantilever beam tests were performed on composites manufactured by hot press, autoclave and 'Quickstep' processes. The 'Quickstep' process was recently developed in Perth, Western Australia for the manufacture of advanced composite components. The values of the mode I critical strain energy release rate (G1d were compared and the results showed that the composite specimens manufactured by the autoclave and the 'Quickstep' process had much higher interlaminar fracture toughness than the specimen produced by the hot press. When compared to specimens manufactured by the hot press, the interlaminar fracture toughness values of the Quickstep and autoclave samples were 38% and 49% higher respectively. The 'Quickstep' process produced composite specimens that had comparable interlaminar fracture toughness to autoclave manufactured composites. Scanning electron microscopy (SEM) was employed to study the topography of the mode I interlaminar fracture surface and dynamic mechanical analysis (DMA) was performed to investigate the fibre/matrix interphase. SEM micrography and DMA spectra indicated that autoclave and 'Quickstep' produced composites with stronger fibre/matrix adhesion than hot press.

Modelling the side impact of carbon fiber tubes

Metallic tubes have been extensively studied for their crashworthiness as they closely resemble automotive crash rails. Recently, the demand to improve fuel economy and reduce vehicle emissions has led automobile manufacturers to explore the crash properties of light weight materials such as fibre reinforced polymer composites, metallic foams and sandwich structures in order to use them as crash barriers. This paper discusses the response of carbon fibre reinforced polymer (CFRP) tubes and their failure mechanisms during side impact. The energy absorption of CFRP tubes is compared to similar Aluminium tubes. The response of the CFRP tubes during impact was modelled using Abaqus finite element software with a composite fabric material model. The material inputs were given based on standard tension and compression test results and the in-plane damage was defined based on cyclic shear tests. The failure modes and energy absorption observed during the tests were well represented by the finite element model.

Coating and functionalization of carbon fibres using a three-step plasma treatment

A three-step plasma treatment—activation, functionalization and polymerization—has been used to deposit a thin plasma polymer with amine groups on carbon fibres (CFs). This plasma polymer has strong adhesion to the CF surface and the amine groups enable strong bonding to a matrix. The CFs were first treated by Ar plasma to activate and clean the surface, followed by O2 plasma to incorporate oxygen-containing functional groups, and finally a heptylamine thin film was deposited using combined continuous wave and pulsed plasma polymerization. Strong adhesion between the plasma polymer and the CF was observed. The fibre strength was not affected by the treatment.

Bond properties of rubber modified epoxy

In this paper, the bond integrity of unmodified and rubber-modified epoxy used for bonding the carbon fibre sheets to the hosting steel surface was investigated. The rigidity of the bonding agent is one of the factors that have a significant role in the premature failure (debonding) of this application. In order to overcome this issue, a series of experiments were conducted on the steel plates using the epoxy resin modified by CTBN and ATBN reactive liquid polymers, in addition to the unmodified epoxy resin. The interface between the carbon fibre matrix and the hosting surface is subjected to a longitudinal shear force for which the corresponding displacement is recorded. The shear stress-strain relationship for the tested specimen is plotted. The result shows that, the bond behaviour of modified epoxy using CTBN and ATBN reactive liquid polymers was improved in terms of ductility and toughness.

Effect of surface functionality of PAN-based carbon fibres on the mechanical performance of carbon/epoxy composites

The performance of composite laminates depends on the adhesion between the fibre reinforcement and matrix, with the surface properties of the fibres playing a key role in determining the level of adhesion achieved. For this reason it is important to develop an in-depth understanding of the surface functionalities on the reinforcement fibres. In this work, multi-scale surface analysis of carbon fibre during the three stages of manufacture; carbonisation, electrolytic oxidation, and epoxy sizing was carried out. The surface topography was examined using scanning electron microscopy (SEM), which revealed longitudinal ridges and striations along the fibre-axis for all fibre types. A small difference in surface roughness was observed by scanning probe microscopy (SPM), while the coefficient of friction measured by an automated single fibre tester showed 51% and 98% increase for the oxidised and sized fibres, respectively. The fibres were found to exhibit heterogeneity in surface energy as evidenced from SPM force measurements. The unsized fibres were much more energetically heterogeneous than the sized fibre. A good correlation was found between fibre properties (both physical and chemical) and interlaminar shear strength (ILSS) of composites made from all three fibre types. © 2014 Elsevier Ltd.

Carbon nexus: a strategic overview and research highlights

Carbon Nexus (www.carbonnexus.com.au) is a globally significant research facility at Deakin University focused on the manufacture and use of carbon fibre. Carbon Nexus represents a partnership between Deakin University and the Victorian Centre for Advanced Materials Manufacturing (VCAMM) and houses two production lines capable of manufacturing industrially relevant quantities of aerospace grade carbon fibre. The facility enables scientists to conduct research into the chemical, mechanical and nano-scale characteristics of new carbon fibre materials produced on site. There is a strong focus on evaluating these new carbon fibre products in composite materials, particularly composites cured using out-of-autoclave techniques. This paper will present an overview of the vision for Carbon Nexus as well as the technical capabilities of both the laboratory scale single tow line and the larger pilot line capable of producing up to 50 tons of carbon fibre per year. Both lines are fully operational and able to convert a range of polymer precursors into carbon fibre. They are representative of world's best practice for carbon fibre manufacturing methods and well suited to conducting energy efficiency studies. Highlights from recent research projects will focus on the effect of the surface treatment and sizing of carbon fibre on fibre-matrix adhesion in composite materials. In addition to this, results from studies of the effect of varying processing parameters on the structure and properties of oxidised polyacrylonitrile and carbon fibre will also be presented.

Experimental investigation on bonding properties of reactive liquid rubber epoxy in CFRP retrofitted concretet members

The load bearing capacity of aging reinforced concrete structures, such as bridges, is increasingly extended with the use of Carbon Fibre Reinforced Polymer (CFRP). Premature failure, which is attributed to the rigid behaviour of the bonding agent (epoxy resin) and the high stresses at the interface region, can occur because of the debonding of CFRP sheets from host surfaces. To overcome the debonding issue, the epoxy resin is modified by different reactive liquid polymers to improve its toughness, flexibility, adhesion, and impact resistance. This study reports the usage of two reactive liquid polymers, namely, liquid Carboxyl-Terminated Butadiene-Acrylonitrile (CTBN) and liquid Amine-Terminated Butadiene-Acrylonitrile (ATBN), to improve the mechanical properties of the commercially available MBrace saturant resin when added to a ratio of 100:30 by weight. The neat and modified epoxies were analysed using the Dynamic Mechanical Thermal Analysis (DMTA) to determine and compare the storage modulus and glass transition temperatures of these materials. Moreover, the bonding strength of neat and modified epoxies was evaluated through single-lap shear tests on CFRP sheets bonded to concrete prisms. The results indicate that the modified resins exhibited improved ductility and toughness and became reasonably flexible compared with the neat epoxy resin. The improved properties will help delay the premature debonding failure in CFRP retrofitted concrete members.

Rapid surface functionalization of carbon fibres using microwave irradiation in an ionic liquid

The modification of carbon fibre surfaces has been achieved using a novel combination of low power microwave irradiation (20 W) in both an ionic liquid (1-ethyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide) and an organic solvent (1,2-dichlorobenzene). The use of the ionic liquid was superior to the organic solvent in this application, resulting in a higher density of surface grafted material. As a consequence, carbon fibres treated in the ionic liquid displayed improved interfacial adhesion in the composite material (+28% relative to untreated fibres) compared to those treated in organic solvent (+18%). The methodology presented herein can be easily scaled up to industrially relevant quantities and represent a drastic reduction in both reaction time (30 min from 24 h) and energy consumption, compared to previously reported procedures. This work opens the door to potential energy and time saving strategies which can be applied to carbon fibre manufacture for high performance carbon fibre reinforced composites.

The influence of processing techniques on the matrix distribution and filtration of clay in a fibre reinforced nanocomposite

A nano-modified matrix based on an epoxy resin and montmorillonite (MMT) layered silicates, was successfully infiltrated through 10 ply of carbon fibre preform. A combined fabrication process of a vacuum assisted resin infusion method (VARIM) followed by a rapid heating rate and mechanical vibration during cure, facilitated the infiltration of the nano-modified matrix through the preform. This was achieved by dispersing the MMT clay in the resin and ensuring that the viscosity of the nano-modified matrix remained low during fabrication. SEM-EDX (energy dispersive X-ray spectroscopy) spectra showed that chemical constituents within MMT clay including silicon, aluminium and magnesium elements had permeated through the fibre preform and were detected throughout the laminate. A homogeneous resin/particle distribution was achieved with the size of clay particles ranging from 100 nm to 1 μm.