The surface finish of thermally aged carbon fibre reinforced composites using E-glass as a surface barrier

This work investigated the effect of woven E-glass mass (25 g/m2, 50 g/m2, 85 g/m2, 135 g/m2) on the painted surface finish of various thermoset (EPIKOTETM RIM935, EPIKOTETM 04434, Ultratec LpTM ES300, Ultratec LpTM SPV6035) carbon fibre composite laminates, before and after aging at 95 °C for 168 h. The as-moulded laminate surfaces were evaluated using surface profilometry techniques and the painted and aged surfaces were evaluated using a wave-scan distinctness of image (DOI) instrument. It was found that the 25 g/m2 E-glass surface layer assisted with reducing the roughness of the as-moulded surfaces and the long-term waviness of the painted surfaces due to the increase in resin-richness at the surface. The EPIKOTETM 04434 resin system that contained diglycidyl ether of bisphenol F (DGEBF) epoxy had the least change in long-term waviness with thermal aging due to the rigid fluorene-based backbone in comparison to the diglycidyl ether of bisphenol A (DGEBA) systems.

Properties of bio-based polymer nylon 11 reinforced with short carbon fiber composites

In this work, micro-composite materials were produced by incorporating 3-mm long reclaimed short carbon fibers into bio-based nylon 11 via melt compounding. A systematic fiber length distribution analysis was performed after the masterbatching, compounding and an injection moulding processes using optical microscopy images. It was found that the large majority of the fibers were within the 200-300 μm in length range after the injection moulding process. The mechanical (flexural and tensile), thermo-mechanical, and creep properties of the injection moulded materials are reported. We found that an enhancement in flexural and Young's modulus of 25% and 14%, respectively, could be attained with 2 wt% carbon fiber loading whilst no significant drawback on the ductility and toughness of the matrix was observed. The creep resistance and recovery of the nylon 11, tested using dynamic mechanical thermal analysis at room temperature and 65°C, was significantly improved by up to 30% and 14%, respectively, after loading with carbon fiber. This work provides an insight into the property improvement of the bio-based polymer nylon 11 using a small amount of a reclaimed engineered material. © 2014 Society of Plastics Engineers.

Prestressed natural fibre spun yarn reinforced polymer-matrix composites

Abstract We report that a prestressing technique similar to that traditionally used in prestressed concrete can improve the mechanical performance of flax fibre spun yarn reinforced polymer-matrix composites. Prestressing a low twist yarn not only introduces tension to the constituent fibres and compressive stress to the matrix similar as in prestressed concretes, but also causes changes to the yarn structure that lead to the rearrangement of fibres within the yarn. Prestressing increases the fibre packing density in yarn, causes fibre straightening, and reduces fibre obliquity in yarn (improved fibre alignment along yarn axis). All these changes contribute positively to the mechanical properties of the natural fibre yarn reinforced composites. Crown

Boron carbide reinforced aluminium matrix composite : physical, mechanical characterization and mathematical modelling

This paper investigates the manufacturing of aluminium-boron carbide composites using the stir casting method. Mechanical and physical properties tests to obtain hardness, ultimate tensile strength (UTS) and density are performed after solidification of specimens. The results show that hardness and tensile strength of aluminium based composite are higher than monolithic metal. Increasing the volume fraction of B4C, enhances the tensile strength and hardness of the composite; however over-loading of B4C caused particle agglomeration, rejection from molten metal and migration to slag. This phenomenon decreases the tensile strength and hardness of the aluminium based composite samples cast at 800 °C. For Al-15 vol% B4C samples, the ultimate tensile strength and Vickers hardness of the samples that were cast at 1000 °C, are the highest among all composites. To predict the mechanical properties of aluminium matrix composites, two key prediction modelling methods including Neural Network learned by Levenberg-Marquardt Algorithm (NN-LMA) and Thin Plate Spline (TPS) models are constructed based on experimental data. Although the results revealed that both mathematical models of mechanical properties of Al-B4C are reliable with a high level of accuracy, the TPS models predict the hardness and tensile strength values with less error compared to NN-LMA models.

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.

Investigation of effective material properties in composites with internal defect or reinforcement particles

This paper is concerned with the investigation of the effective material properties of internally defective or particle-reinforced composites. An analysis was carried out with a novel method using the two-dimensional special finite element method mixing the concept of equivalent homogeneous materials. A formulation has been developed for a series of special finite elements containing an internal defect or reinforcement in order to assure the high accuracy especially in the vicinity of defects or reinforcements. The adoption of the special finite element can greatly simplify numerical modeling of particle-composites. The numerical result provides the effective material properties of particle-reinforced composite and explains that the size of particles has great influence on the material properties. Numerical examples also demonstrate the validity and versatility of the proposed method by comparing with existing results from literatures.

Equal channel angular pressing of metal matrix composites: effect on particle distribution and fracture toughness

An Al6061-20%Al₂O₃ powder metallurgy (PM) metal matrix composite (MMC) with a strongly clustered particle distribution is subjected to equal channel angular pressing (ECAP) at a temperature of 370 °C. The evolution of the homogeneity of the particle distribution in the material during ECAP is investigated by the quadrat method. The model proposed by Tan and Zhang [Mater Sci Eng 1998;244:80] for estimating the critical particle size which is required for a homogeneous particle distribution in PM MMCs is extended to the case of a combination of extrusion and ECAP. The applicability of the model to predict a homogeneity of the particle distribution after extrusion and ECAP is discussed. It is shown that ECAP leads to an increase of the  uniformity of the particle distribution and the fracture toughness.

Influence of helium atmospheric plasma treatment on surface and fracture-mechanical behaviour of quickstepTM cured bio-composites

This work investigated the potential of improving flexural properties of natural fiber (jute) reinforced biocomposites by atmospheric pressure helium plasma treatment. Composites were made by the use of combined hand lay-up and vacuum bagging technique followed by newly developed Australia patented Quickstep^TM curing. The physical properties of helium plasma modified fibers were investigated by means of wettability time, coefficient of friction (COF), atomic force microscopy (AFM) and chemical nature of the surface with ATR-FTIR and XPS. There was found a logical correlation between physical and chemical characteristics of the surface of fiber with the fracture mechanical behavior of their resulting biocomposites. In addition, the use of helium atmospheric plasma treatment prior to Quickstep^TM process has proved to be a potential way to positively alter the fracture-mechanical behavior of biocomposites. This study will lead to new commercial applications of natural fiber jute for the composite industry that go beyond wrapping and packaging.

Tensile behaviour of non-uniform fibres and fibrous composites

This work investigates the tensile behaviour of non-uniform fibres and fibrous composites. Wool fibres are used as an example of non-uniform fibres because they're physical, morphological and geometrical properties vary greatly not only between fibres but also within a fibre. The focus of this work is on the effect of both between-fibre and within-fibre diameter variations on fibre tensile behaviour. In addition, fit to the Weibull distribution by the non-brittle and non-uniform visco-elastic wool fibres is examined, and the Weibull model is developed further for non-uniform fibres with diameter variation along the fibre length. A novel model fibre composite is introduced to facilitate the investigation into the tensile behaviour of fibre-reinforced composites. This work first confirms that for processed wool, its coefficient of variation in break force can be predicted from that of minimum fibre diameters, and the prediction is better for longer fibres. This implies that even for processed wool, fibre breakage is closely associated with the occurrence of thin sections along a fibre, and damage to fibres during processing is not the main cause of fibre breakage. The effect of along-fibre diameter variation on fibre tensile behaviour of scoured wool and mohair is examined next. Only wet wool samples were examined in the past. The extensions of individual segments of single non-uniform fibres are measured at different strain levels. An important finding is the maximum extension (%) (Normally at the thinnest section) equals the average fibre extension (%) plus the diameter variation (CV %) among the fibre segments. This relationship has not been reported before. During a tensile test, it is only the average fibre extension that is measured. The third part of this work is on the applicability of Weibull distribution to the strength of non-uniform visco-elastic wool fibres. Little work has been done for wool fibres in this area, even though the Weibull model has been widely applied to many brittle fibres. An improved Weibull model incorporating within-fibre diameter variations has been developed for non-uniform fibres. This model predicts the gauge length effect more accurately than the conventional Weibull model. In studies of fibre-reinforced composites, ideal composite specimens are usually prepared and used in the experiments. Sample preparation has been a tedious process. A novel fibre reinforced composite is developed and used in this work to investigate the tensile behaviour of fibre-reinforced composites. The results obtained from the novel composite specimen are consistent with that obtained from the normal specimens.

Microstructural development in Al/MgAl2O4 in situ metal matrix composite using value-added silica sources

Al/MgAl2O4 in situ metal matrix composites have been synthesized using value-added silica sources (microsilica and rice husk ash) containing ~97% SiO2 in Al-5 wt.% Mg alloy. The thermodynamics and kinetics of MgAl2O4 formation are discussed in detail. The MgO and MgAl2O4 phases were found to dominate in microsilica (MS) and rice husk ash (RHA) value-added composites, respectively, during the initial stage of holding the composites at 750 °C. A transition phase between MgO and MgAl2O4 was detected by the scanning electron microscopy and energy-dispersive spectroscopy (SEM–EDS) analysis of the particles extracted from the composite using 25% NaOH solution. This confirms that MgO is gradually transformed to MgAl2O4 by the reaction 3SiO2(s)+2MgO(s)+4Al(l)→2MgAl2O4(s)+3Si(l). The stoichiometry of MgAl2O4, n, computed by a new methodology is between 0.79 and 1.18. The reaction between the silica sources and the molten metal stopped after 55% of the silica source was consumed. A gradual increase in mean MgAl2O4 crystallite size, D, from 24 to 36 nm was observed in the samples held for 10 h.

A study on the thermodynamics of in situ MgAl2O4/Al MMC formation using amorphous silica sources

MgAl₂O₄ (spinel) is considered as a commercially important ceramic reinforcement in MMC fabrication because of the possible tailorable properties imparted with Al for many applications. Generally, any oxygen source, i.e., the dissolved oxygen, or pure oxygen atmosphere or atmospheric oxygen is sufficient for the formation of MgAl₂O₄ in Al–Mg alloy. Among all the reactive oxygen sources, the reactivity of SiO₂ with Al alloy is found to be higher. Amorphous silica is highly reactive in nature compared to crystalline silica. The present study has examined the thermodynamics of MgAl₂O₄ formation in Al–Mg alloy by amorphous silica sources with the aid of differential thermal analyzer (DTA) and the simulated experiments. The dissolution of Si and the formation of MgAl₂O₄ are detected as the endothermic peak and the immediate exothermic peak respectively in DTA curves and the presence of MgAl₂O₄ is confirmed by the XRD of the simulated sample. The MgO formed due to the oxidation of Mg in Al–Mg alloy has been found to influence the MgAl₂O₄ formation.

Synthesis of an Al/MgAl2O4 in situ metal matrix composite from silica gel

An aluminum/MgAl2O4 in situ metal matrix composite has been synthesized using silica gel containing B98% SiO2 in an Al–5Mg alloy. The thermodynamics and kinetics of MgAl2O4 formation have been discussed in detail. A transition phase of composition between MgO and MgAl2O4 has been detected in the SEM-EDS analysis of the particles extracted from the composite by a 25% NaOH solution. This confirms the gradual transformation of MgO to MgAl2O4 by the reaction 3SiO2(s)12MgO(s)14Al(l)-2MgAl2O4(s)13Si(l). The stoichiometry, n, of MgAl2O4 has been found to sustain close to 1 and the crystallite growth of MgAl2O4 has been stopped at DB30 nm in the composites held at 7501C up to 10 h.

Thermodynamics and kinetics of the formation of Al2 O3/ MgAl2O4/MgO in Al-Silica metal matrix composite

The formation of Al₂O₃, MgAl₂O₄, and MgO has been widely studied in different Al base metal matrix composites, but the studies on thermodynamic aspects of the Al₂O₃/ MgAl₂O₄/MgO phase equilibria have been limited to few systems such as Al/Al₂O₃ and Al/SiC. The present study analyzes the Al₂O₃/MgAl₂O₄ and MgAl₂O₄/MgO equilibria with respect to the temperature and the Mg content in Al/SiO2 system using an extended Miedema model. There is a linear and parabolic variation in Mg with respect to the temperature for MgAl₂O₄/MgO and Al₂O₃/MgAl₂O₄ equilibria, respectively, and the influence of Si and Cu in the two equilibria is not appreciable. The experimental verification has been limited to MgAl₂O₄/MgO equilibria due to the high Mg content (≥0.5 wt pct) required for composite processing. The study has been carried out on two varieties of Al/SiO₂ composites, i.e., Al/Silica gel and Al/Micro silica processed by liquid metallurgy route (stir casting route). MgO is found to be more stable compared to MgAl₂O₄ at Mg levels ≥5 and 1 wt pct in Al/Silica gel and Al/Micro silica composites, respectively, at 1073 K. MgO is also found to be more stable at lower Mg content (3 wt pct) in Al/Silica gel composite with decreasing particle size of silica gel from 180 micron to submicron and nanolevels. The MgO to MgAl₂O₄ transformation has taken place through a series of transition phases influenced by the different thermodynamic and kinetic parameters such as holding temperature, Mg concentration in the alloy, holding time, and silica particle size.

Preparation, characterization and dielectric properties of temperature stable SrTiO3/PEEK composites for microwave substrate applications

Poly(ether ether ketone) (PEEK) is a potential candidate for electronic applications due to its low permittivity, low loss, high melting point, better chemical resistance, excellent insulating properties and easy processibility. Present paper discusses the preparation and characterization of SrTiO3 filled PEEK composite for microwave substrate applications. The dielectric constant, dielectric loss and temperature variation of dielectric constant of the composites have been studied up to 1 MHz using an Impedance Analyzer. Different theoretical approaches have been employed to predict the effective permittivity of composite systems and the results are compared with that of the experimental data. The crystallinity of the bulk composite is studied by X-ray diffraction studies. Scanning electron microscopic technique has been employed to study the dispersion of the particulate filler in PEEK matrix. Vickers hardness of pure and filled PEEK composite has been measured using Microhardness Tester. The effect of particle size on the dielectric as well as mechanical properties of SrTiO3/PEEK composite system is also studied by incorporating micronsize and nanosize fillers. Present study shows that a temperature stable composite can be realized by judiciously selecting appropriate filler concentration in the PEEK matrix.

Carbon nanotubes reinforced electrospun polymer nanofibres

With the rapid development in nanoscience and nanotechnology, there is an ever increasing demand for polymer fibres of diameters down to a nanometre scale having multiple functionalities. Electrospinning, as a simple and efficient nanofibre-making technology, has been used to produce polymer nanofibres for diverse applications. Electrospun nanofibres
based on polymer/carbon nanotube (CNT) composites are very attractive multifunctional nanomaterials because they combine the remarkable mechanical and electronic properties of CNTs and the confinement-enhanced CNTs alignment within the nanofibre structure, which could greatly improve the fibre mechanical, electrical and thermal properties. In this chapter, we summarise recent research progress on electrospun CNTs/polymer nanofibres, with an emphasis on fibre mechanical properties and structure-property attributes. Outlook towards the challenge and future directions in this field is also presented.