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.

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.

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.

Improvement of coating durability, interfacial adhesion and compressive strength of UHMWPE fiber/epoxy composites through plasma pre-treatment and polypyrrole coating

Ultra-high-molecular-weight polyethylene (UHMWPE) fibers have exceptionally higher specific strength and stiffness compared with other high-performance fibers. However, the interfacial adhesion and compressive performance of UHMWPE fiber-reinforced polymer composites (FPCs) are extremely low. The challenges are to achieve load transfer at the interface between the fiber and matrix at a molecular level. Here, we show that plasma pre-treatment of UHMWPE fibers followed by coating with polypyrrole (PPy) results in an 848% improvement in the interfacial adhesion and 54% enhancement in compressive performance. This method takes advantage of a toughening mechanism observed in spider silk and collagen, which the hydrogen bond power the load transfer. The results showed that these improvements of interfacial adhesion and compressive strength were attributed to hydrogen-bonding interactions between the plasma pre-treated UHMWPE and PPy, which improves the fiber-matrix-fiber load transfer process. In addition, the hydrogen-bonded PPy coatings also endowed durability electrical conductivity properties of the UHMWPE fiber.

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.

Improving the dispersion and mechanical properties of epoxy/carbon nanotube composites

The incorporation and uniform dispersion of carbon nanotubes (CNTs) in polymer matrix could facilitate engineers to create high performance nanocomposites that potentially compete with most advanced materials in nature. The unique combination of outstanding mechanical, thermal, and electrical properties of CNTs makes them excellent nanofillers for the fabrication of advanced materials. Successful enhancement in mechanical properties via reinforcement is expected only when the nanofillers are well dispersed in the polymer matrix. Moreover, the orientation as well as the CNT/matrix interfacial strength also determines the effective physical properties of the nanocomposites. However, CNTs typically assemble to give bundles, which are heavily entangled to each other with a high aspect ratio and a large π-electronic surface. In this work, we outline some preliminary results in preparing high performance epoxy composites. Composites with fine dispersion and superior mechanical properties were prepared using epoxy and multiwalled carbon nanotubes (MWCNTs). The fine dispersion of the nanocomposites can be identified in the high resolution SEM image shown in Figure 1. This method can provide an alternative route for the preparation of new structural and functional nanocomposites.

Thermally flexible epoxy/cellulose blends mediated by an ionic liquid

Blends between the widely used thermoset resin, epoxy, and the most abundant organic material, natural cellulose are demonstrated for the first time. The blending modification induced by charge transfer complexes using a room temperature ionic liquid, leads to the formation of thermally flexible thermoset materials. The blend materials containing low concentrations of cellulose were optically transparent which indicates the miscibility at these compositions. We observed the existence of intermolecular hydrogen bonding between epoxy and cellulose in the presence of the ionic liquid, leading to partial miscibility between these two polymers. The addition of cellulose improves the tensile mechanical properties of epoxy. This study reveals the use of ionic liquids as a compatible processing medium to prepare epoxy thermosets modified with natural polymers.

One-pot synthesis of aminated multi-walled carbon nanotube using thiol-ene click chemistry for improvement of epoxy nanocomposites properties

A non-oxidative method based on thiol-ene click chemistry for functionalization of multi-walled carbon nanotube (CNT) was performed in order to improve the interfacial interactions between epoxy matrix and CNT. In this way, the CNT was aminated using 2-aminoethanethiol hydrochloride radicals thermally produced by a peroxide radical initiator. The aminated CNT (CNT-NH2) was characterized by FTIR, TGA, and solubility evaluations, confirming that thiol radicals are successfully grafted onto the CNT surface with a proper yield. Various percentages of pure CNT (p-CNT) and CNT-NH2 were then incorporated into epoxy matrix to evaluate the effect of the functionalization of CNT on thermal, mechanical, and morphological properties. The nanocomposites were characterized by DMA, tensile testing, and TGA. Results showed that glass transition temperature, tensile properties and thermal stability of epoxy nanocomposites containing CNT-NH2 improves significantly compared to those containing unmodified CNT. These results prove the role of amino-functionalization in improving the interfacial adhesion between epoxy and CNT, which was further confirmed by morphological observations of fracture surfaces of the nanocomposites.

Manufacturing process effects on the mode I interlaminar fracture toughness and nanocreep properties of CFRP

Quickstep ™ is a fluid filled floating mould technology which was recently developed by an Australian company of the same name. The Quickstep and conventional autoclave manufacture of composites were compared by investigating the mode I interlaminar fracture toughness and nanocreep propeties of HexPly914 carbon epoxy composites. It was found that composites cured using the Quickstep technology had significantly higher fracture toughness (1.8 times) than the composites cured via autoclave for this system. DMTA (dynamic mechanical thermal analysis) results showed a higher Tg (glass transition temperature) for the material manufactured by the Quickstep than that cured by the autoclave. FTIR (Fourier transform infrared spectroscopy) spectra did not indicate any difference in cure chemistry between the two processes. Nanocreep experiments were performed to explore the viscoelastic properties of the epoxy matrix of composites. The KelvinVoigt three-element model was applied to analyse the indentation creep behaviour of both composites.

Mechanical properties of graphene films enhanced by homo-telechelic functionalized polymer fillers via π-π Stacking interactions

© 2015 Elsevier Ltd. All rights reserved. Most researches on graphene/polymer composites are focusing on improving the mechanical and electrical properties of polymers at low graphene content instead of paying attention to constructing graphene's macroscopic structures. In current study the homo-telechelic functionalized polyethylene glycols (FPEGs) were tailored with π-orbital-rich groups (namely phenyl, pyrene and di-pyrene) via esterification reactions, which enhanced the interaction between polyethylene glycol (PEG) molecules and chemical reduced graphene oxide (RGO) sheets. The π-π stacking interactions between graphene sheets and π-orbital-rich groups endowed the composite films with enhanced tensile strength and tunable electrical conductivity. The formation of graphene network structure mediated by the FPEGs fillers via π-π stacking non-covalent interactions should account for the experimental results. The experimental investigations were also complemented with theoretical calculation using a density functional theory. Atomic force microscope (AFM), scanning electron microscope (SEM), X-ray diffraction (XRD), nuclear magnetic resonance (NMR), thermal gravimetric analysis (TGA), UV-vis and fluorescence spectroscopy were used to monitor the step-wise preparation of graphene composite films.