Hierarchical composites from carbon fibres electrosprayed with carbon nanotubes

 This research developed a novel method for coating carbon nanotubes onto carbon fibre surfaces. It provided valuable guidance for producing various CNT morphologies on fibre surfaces. More importantly, the produced hybrid structures improved interfacial bonding in composites significantly, and this research will explore more potential applications of new generation composites.

A systematic investigation into a novel method for preparing carbon fibre–carbon nanotube hybrid structures

By electrospraying solvent dispersed carbon nanotubes (CNTs) with a binder onto carbon fibre (CF), hybrid structures, with an end aim to improve interfacial bonding in composites, were formed. The electrospray parameters controlling the modification of the CNT morphologies were studied. High-speed camera observations found applied voltage was critical for determining spray mode development. Electric field simulations revealed a concentrated electric field region around each fibre. Both voltage and distance played an important role in determining the CNT morphology by mediating anchoring strength and electric field force. The forming mechanism investigation of different surface morphologies suggested that binder with appropriate wetness gives freedom to the CNTs, allowing them to orientate radially from the CF surface. Linear density (LD) measurements and thermogravimetric analysis revealed that a 10 min coating increased the LD of a single CF filament by up to 31.7% while a 1 h treatment increased fibre bundle mass by 1%.

Cellulose-derived carbon fibers produced via a continuous carbonization process: investigating precursor choice and carbonization conditions

Here, the carbonization of two Lyocell type regenerated cellulose fibres is reported. Commercially available Lyocell as well as the experimental Lyocell type fibre known as Ioncell-F spun from the ionic liquid 1,5-diazabicyclo[4.3.0]non-5-ene-1-ium acetate ([DBNH]OAc) is investigated, which supports higher draw ratio and thus improves precursor mechanical properties. Lyocell fibres are known to have improved mechanical properties over other regenerated cellulose fibres and are therefore considered to be better carbon fibre precursor candidates. The Lyocell fibres used in this study are carbonized utilizing a scaled down identical replica of an in use carbon fibre line. The importance of this is the ability to assess the performance of the Lyocell fibres under more realistic continuous carbonization processing conditions. The tensile properties, morphology, and chemical composition of all fibres are determined. It is shown that by changing the carbonization temperature and atmosphere fibres with different mechanical properties and diameter can be produced. Elemental analysis confirms that each fibre has a carbon content of ≥90%.

Surface analysis of environmentally exposed painted composites manufactured from Quickstep and autoclave processes

The surface finishes of laminates produced by Quickstep™ and autoclave processes for use in automotive outer skin panels were compared. Automotive quality, painted carbon fibre samples, manufactured via both processes, were exposed to typical exposure environments including combinations of temperature (70, 120, 170°C), UV-B, humidity (95% RH) and immersion in water.

The microscopy and surface roughness results demonstrated that the surfaces produced by the Quickstep process were less susceptible to damage in the aging environments than the surfaces of the autoclaved samples. Quickstep samples displayed surface bubbling of only 5 μm, compared to the autoclaved surface bubbles which reached a diameter of 30 mm before bursting, with complete delamination occurring between the paint and the composite. The surface roughness measurements revealed the autoclave samples (Ra = 0.72 μm) were up to three times the roughness of the Quickstep samples (Ra = 0.23 μm).

Characterization of the moisture absorption and thermal ageing behaviour of polymeric composite systems using Raman spectroscopy

Advanced polymeric materials and their respective composites are fast becoming one of the world's most frequently used engineering materials. They find application in the manufacture of e.g. boat hulls, high performance motor vehicles, aircraft components and sports goods. Their high specific strength and specific stiffness give them the edge in applications where weight savings are critical, but their long-term durability is often questioned. These materials are susceptible to environmental conditions such as temperature and humidity. There is also a lack of relevant data, due to the long time-scales required for testing. In this study, the Raman technique has been used to monitor the degradation of two composite systems, namely: a rubber toughened vinylester material used in the marine industry and a high temperature bismaleimide/carbon fibre aerospace composite. Preliminary Raman studies show that the toughening rubber particles dispersed in the cured vinylester resin are leached out during hygrothermal ageing. The weight gain during ageing suggests that this leaching process occurs concurrently with the absorption of water molecules. An increase in the degree of cross-linking is observed when bismaleimide/carbon fibre composite is aged at high temperature. This cross- linking tendency decreases with increasing depth within the carbon fibre bundle.

Hierarchical development of training database for artificial neural network-based damage identification

Though serving as an effective means for damage identification, the capability of an artificial neural network (ANN) for quantitative prediction is substantially dependent on the amount of training data. In virtue of a concept of “Digital Damage Fingerprints” (DDF), a hierarchical approach for the development of training databases was proposed for ANN-based damage identification. With the object of exploiting the capability of ANN to address the key questions: “Is there damage?” and “Where is the damage?”, the amount of training data (damage cases) was increased progressively. Mutuality was established between the quantity of training data and the accuracy of answers to the two questions of interest, and was experimentally validated by identifying the position of actual damage in carbon fibre-reinforced composite laminates. The results demonstrate that such a hierarchical approach is capable of offering prediction as to the presence and location of damage individually, with substantially reduced computational cost and effort in the development of the ANN training database.

Strain rate effects on the energy absorption of rapidly manufactured composite tubes

Quasi-static and intermediate rate axial crush tests were conducted on tubular specimens of Carbon/Epoxy (Toray T700/G83C) and Glass/Polypropylene (Twintex). The quasi-static tests were conducted at 10 mm/min (1.67 x 10¯⁴ m/s); five different crush initiators were used. Tests at intermediate rates were performed at speeds of 0.25, 0.5, 0.75, 1, 2, and 4m/s. Modes of failure and specific energy absorption (SEA) values were studied. The highest SEA measured was 86 kJ/kg. This value was observed using Carbon/Epoxy samples at quasi static rates with a 45° chamfer initiator. The highest energy absorption for Twintex tubes was observed to be 57.56 kJ/kg during 45° chamfer initiated tests at 0.25 m/s. Compared with steel and aluminium, SEA values of 15 and 30 kJ/kg, respectively, the benefits of using composite materials in crash structures become apparent.

Quickstep

Quickstep✹ is a novel technology for composite materials manufacturing. Characterisation of carbon fibre reinforced polymer composites cured both conventionally and with the low cost Quickstep process revealed a higher glass transition temperature, enhanced fracture toughness and better impact resistance for the Quickstep composite laminates.

Mechanical characterizations of thick laminated composites before and after bonded repair

One set of composite laminates was manufactured from bi-directional carbon fibre woven cloth pre-impregnated with epoxy resin and used to establish experimental techniques. Another, similar set was used for extensive data collection. One other set of laminates, manufactured from uni-directional carbon fibre, was also subjected to extensive tests to represent a different material. The results give the pre and post characterizations of repaired composite materials; outlining at each stage the losses and gains of structural strength and stiffness and discusses the difficulties experienced.

Characterisation of an out-of-autoclave resin film infusion process for textile composites

A new method to manufacture damage tolerant textile composites, which combines Resin Film Infusion with a fast and cost·efficient curing technology QuickstepTM, was investigated. The effect of process parameters on resin flow through carbon fibre preforms was analysed and model-based parameter optimisation resulted in considerable improvement of resin flow properties.

Development of novel crash structures

In this thesis, the crash properties of carbon fibre composites were studied in detail. Also, novel materials were developed and characterized so that they could potentially be used for automotive crash applications.

Structural composites embedded with lithium polymer batteries

Structural battery composites that concurrently carry load and store electric energy will
transform future vehicles. They can replace inert structural components and simultaneously provide supplementary power for light load applications. Rechargeable lithium polymer battery cells are embedded into carbon fibre/epoxy matrix composite laminates, which are then tested under tension and three-point bending to investigate the mechanical and electrical performances of structural batteries. The experimental results show that the integration of battery cells into composite laminates has negligible impact on the mechanical strengths of the composite structures. Furthermore, the battery cells remain 95% effective at loads up to about 60% of the ultimate flexural failure load and 50% of the ultimate tensile failure load.

Effects of mechanical deformation on electric performance of rechargeable batteries embedded in load carrying composite structures

Integrating rechargeable battery cells with fibre reinforced polymer matrix composites is a promising technology to enable composite structures to concurrently carry load and store electric energy, thus significantly reducing weight at the system level. To develop a design criterion for structural battery composites, rechargeable lithium polymer battery cells were embedded into carbon fibre/epoxy matrix composite laminates, which were then subjected to tensile, flexural and compressive loading. The electric charging/discharging properties were measured at varying levels of applied loads. The results showed that degradation in battery performance, such as voltagea and energy storage capacity, correlated well with the applied strain under three different loading conditions. Under compressive loading, battery cells, due to their multilayer construction, were unable to prevent buckling of composite face sheets due to the low lateral stiffness, leading to lower compressive strength that sandwich panels with foam core.

Analyzing track sprint cyclists' performances using position-specific maximal-torque and power-cadence relationships

Previous studies have demonstrated the importance of maximal Torque-Cadence (T-C) and Power-Cadence (P-C) relationships, for the performances of world class track sprint cyclists. If these relationships are affected by the function of the lower limb muscles, the ability of cyclists to generate torque and power at a given cadence may vary depending on their riding position. During sprint events (individual and team sprints and Keirin), cyclists alternate between standing and seated positions. The T-C and P-C relationships may change with the position adopted by the cyclists. PURPOSE: The aim of this study was to evaluate the necessity to define position specific maximal T-C and P-C relationships. METHODS: Eight junior elite track cyclists from the National Talent Identification squad undertook two inertial-load tests that consisted of four all-out sprints each. One test was undertaken at the velodrome in a standing position on a carbon fibre track bike, and the other test was completed in a seated position on an air-braked stationary ergometer. A calibrated SRM power meter interfaced to a custom instrumentation package was used for all mechanical measurements. Maximal T-C and P-C relationships were analysed to calculate maximal Torque (T0), maximal Power (Pmax) and optimal pedalling cadence (PCopt). RESULTS: All individual T-C and P-C relationships obtained for both body positions were fitted by linear regressions (r2=0.95 ± 0.02) and second order polynomials (r2=0.96 ± 0.01), respectively. T0 was higher (209 ± 2.2N.m vs. 177.0 ± 3.9N.m, p<0.05), PCopt was lower (112.5 ± 11.4rpm vs. 120.1 ± 6.7rpm, p<0.05), and Pmax was higher (1261 ± 235W vs. 1076 ± 183W, p<0.05) in standing position compared to seated position. CONCLUSION: Analysis of track sprint cyclists’ performances can be improved by the determination of position-specific maximal T-C and P-C relationships .

Improving performance of CFRP retrofitted RC members using rubber modified epoxy (ongoing research)

Although the method of external attachment of CFRP to the concrete members is the most effective and economical solution for strengthening and repairing concrete structure in the century, the bonding issue between CFRP and the hosting surface still a challenge for the structural engineers. Many solutions are proposed to overcome the early debonding failure in the strengthened members. This paper reports an ongoing experimental program for testing CFRP retrofitted RC beams and slabs. Fifteen RC beams of dimensions 150x250x2300mm and twelve two- way RC slabs of size 85x1670x1670mm will be strengthened using different types of epoxies, different configurations and variable number of layers of CFRP strips (MBrace-230). Rubber modified epoxy will be used for carbon fibre external attachment using wet lay-up method. Loading frame of 500 kN capacity will be used for beams testing. While for applying uniformly distributed load on the slabs a purpose built attachment will be used. The experimental results will report on the ultimate load, failure mode, mid-span deflection, strains readings in different locations and the ductility for both groups of strengthened beams and slabs. A mathematical model will be developed to predict the behavior of RC beams and two-way slabs.