Surface analysis of carbon fibre epoxy composites

This thesis investigated the surface finish of rapidly cured composites for automotive body panels. Findings showed that curing composites with rapid heating rates increased surface roughness, although it improved paint adhesion to the substrate. This thesis also highlighted the need for surface barriers to reduce fibre print through during aging.

Characterisation of out-of-autoclave carbon fibre composites

Out-of-autoclave processing parameters were tailored to investigate the effect of resin viscosity on mechanical performance. Faster heating rates improved the shear and fracture mechanisms of carbon fibre composites by improving their fibre to matrix adhesion, as a result of a decrease in resin viscosity.

Functionalisation of carbon fibre toward enhanced fibre/matrix adhesion

This study developed new methodologies to enhance the performance of carbon fiber in epoxy-based composites. A unique interdisciplinary approach of organic chemistry and engineering resulting in excellent real world outcomes.

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.

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.

Characterization and analysis of delamination fracture and nanocreep properties in carbon epoxy composites manufactured by different processes

Delamination resistance and nanocreep properties of 2/2 twill weave carbon epoxy composites manufactured by hot press, autoclave, and Quickstep^TM process are characterized and analyzed. Quickstep is a fluid filled, balanced pressure heated floating mold technology, which is recently developed in Perth, Western Australia for the manufacture of advanced composite components. Mode I and Mode II interlaminar fracture toughness tests, and nanoindentation creep tests on matrix materials show that the fast ramp rate of the Quickstep process provides mechanical properties comparable to that of autoclave at a lower cost for composite manufacturing. Low viscosity during ramping process and good fiber wetting are believed to be the reasons that this process produces composites with high delamination and creep-resistant properties. Nanocreep properties are analyzed using a Kelvin–Voigt model.

Manufacturing influence on the delamination fracture behavior of the T800H/3900-2 carbon fiber reinforced polymer composites

'Torayca' T800H/3900-2 is the first material qualified on Boeing Material Specification (BMS 8-276) which utilizes the thermoplastic-particulate interlayer toughening technology. Two manufacturing processes, the autoclave process and the fast heating rated Quickstep™ process, were employed to cure this material. The Quickstep process is a unique composite production technology which utilizes the fast heat transfer rate of fluid to heat and cure polymer composite components. The manufacturing influence on the mode I delamination fracture toughness of laminates was investigated by performing double cantilever beam tests. The composite specimens fabricated by two processes exhibited dissimilar delamination resistance curves (R-curves) under mode I loading. The initial value of fracture toughness GIC-INIT was 564 J/m2 for the autoclave specimens and 527 J/m2 for the Quickstep specimens. However, the average propagation fracture toughness GIC-PROP was 783 J/m2 for the Quickstep specimens, which was 2.6 times of that for the autoclave specimens. The mechanism of fracture occurred during delamination was studied under scanning electron microscope (SEM). Three types of fracture were observed: the interlayer fracture, the interface fracture, and the intralaminar fracture. These three types of fracture played different roles in affecting the delamination resistance curves during the crack growth. More fiber bridging was found in the process of delamination for the Quickstep specimens. Better fiber/matrix adhesion was found in the Quickstep specimens by conducting indentation-debond tests.

Carbon nanotube polymer composites and nanofibres

This study examined how carbon nanotubes (CNTs) in electrospun polymeric nanofibres influenced the polymer morphology, and how polymer morphology change induced by different post-electrospinning treatments influenced CNT-polymer interaction and nanofibre properties. The results showed that both the polymer structure and morphology played important roles in determining the composite and nanofibre properties.

Self-assembled natural rubber/multi-walled carbon nanotube composites using latex compounding techniques

Functionalization of multi-walled carbon nanotubes (MWCNTs) plays an important role in eliminating nanotube aggregation for reinforcing polymeric materials. We prepared a new class of natural rubber (NR)/MWCNT composites by using latex compounding and self-assembly technique. The MWCNTs were functionalized with mixed acids (H2SO₄/HNO₃ = 3:1, volume ratio) and then assembled with poly (diallyldimethylammonium chloride) and latex particles. The Fourier transform infrared spectroscopy, transmission electron microscopy, and scanning electron microscopy were used to investigate the assembling mechanism between latex particles and MWCNTs. It is found that MWCNTs are homogenously dispersed in the natural rubber (NR) latex as individual nanotubes since strong self-aggregation of MWCNTs has been greatly depressed with their surface functionalization. The well-dispersed MWCNTs produce a remarkable increase in the tensile strength of NR even when the amount of MWCNTs is only 1 wt.%. Dynamic mechanical analysis shows that the glass transition temperature of composites is higher and the inner-thermogenesis and thermal stability of NR/MWCNT composites are better, when compared to those of the pure NR. The marked improvement in these properties is largely due to the strong interfacial adhesion between the NR phase and MWCNTs. Functionalization of MWCNTs represents a potentially powerful technology for significant reinforcement of natural rubber materials.

High strain rate tensile properties of rapidly cured woven carbon fibre composites

Tensile tests at high speeds corresponding to automotive crash events were conducted to understand the dynamic properties of rapidly cured woven carbon fiber composites. The High Strain Rate (HSR) experiments were conducted on a servo-hydraulic machine at constant velocities up to a maximum of 25 m/s (82 ft/s). Results from HSR tests were compared with the static results to determine the rate sensitivity of the composite. A high speed camera was used to capture the failure at HSR. The tensile properties of rapidly cured laminate were compared to oven cured laminate to justify its productivity while maintaining the desired properties. The methodology used to achieve constant velocity during HSR tests is discussed in detail. The specimen geometry was specially designed to suit the test rig and to achieve high speeds during tests. All the specimens failed with linear elasticity until sudden brittle fracture. The Scanning Electron Microscopy (SEM) images of the fracture zone were used to identify the failure modes observed at static and high strain rates.

Tailoring the surface chemistry of carbon fiber and E-glass composites for improved adhesion

The main challenges in the manufacture of composite materials are low surface energy and the presence of silicon-containing contaminants, both of which greatly reduce surface adhesive strength. In this study, carbon fiber (CF) and E-glass epoxy resin composites were surface treated with the Accelerated Thermo-molecular adhesion Process (ATmaP). ATmaP is a multiaction surface treatment process where tailored nitrogen and oxygen functionalities are generated on the surface of the sample through the vaporization and atomization of n-methylpyrrolidone solution, injected via specially designed flame-treatment equipment. The treated surfaces of the polymer composites were analyzed using XPS, time of flight secondary ion mass spectrometry (ToF-SIMS), contact angle (CA) analysis and direct adhesion measurements. ATmaP treatment increased the surface concentration of polar functional groups while reducing surface contamination, resulting in increased adhesion strength. XPS and ToF-SIMS showed a significant decrease in silicon-containing species on the surface after ATmaP treatment. E-glass composite showed higher adhesion strength than CF composite, correlating with higher surface energy, higher concentrations of nitrogen and CO functional groups (from XPS) and higher concentrations of oxygen and nitrogen-containing functional groups (particularly C₂H₃O⁺ and C₂H₅NO⁺ molecular ions, from ToF-SIMS).

Structure and properties of self-assembled narural rubber/multi-walled carbon nanotube composites

Natural rubber (NR)/multi-walled carbon nanotube (MWCNTs) composites were prepared bycombining self-assembly and latex compounding techniques. The acid-treated MWCNTs (H2SO4: HNO3=3:1,volume ratio) were self-assembled with poly (diallyldimethylammonium chloride) (PDDA) through electrostaticadhesion. In the second assembling, NR/MWCNTs composites were developed by mixing MWCNTs/PDDAsolution with NR latex. The results show that MWCNTs are homogenously distributed throughout the NRmatrix as single tube and present a great interfacial adhesion with NR phase when MWCNTs contents areless than 3 wt%. Moreover, the addition of the MWCNTs brings about the remarkable enhancement in tensilestrength and crosslink density compared with the NR host, and the data peak at 2 wt% MWCNTs loadings.When more MWCNTs are loaded, aggregations of MWCNTs are gradually generated, and the tensile strengthand crosslink both decrease to a certain extent.