J. Compos. Sci., Volume 4, Issue 4 (December 2020) – 48 articles

Some treatment options available to repair bone defects are the use of autogenous and allogeneic bone grafts. The drawback of the first one is the donor site’s limitation and the need for a second operation on the same patient. In the allograft method, the problems are associated with transmitted diseases and high susceptibility to rejection. As an alternative to biological grafts, polymers can be used in bone repair. Some polymers used in the orthopedic field are poly(methyl methacrylate), poly(ether-ether-ketone), and ultra-high molecular weight polyethylene (UHMWPE). UHMWPE has drawn much attention since it combines low friction coefficient and high wear and impact resistance. However, UHMWPE is a bioinert material, which means that it does not interact with the bone tissue. UHMWPE composites and nanocomposites with hydroxyapatite (HA) are widely studied in the literature to mitigate these issues. HA is the main component of the inorganic phase in the natural bone, and the addition of this bioactive filler to the polymeric matrix aims to mimic bone composition. This brief review discusses some polymers used in orthopedic applications, focusing on the UHMWPE/HA composites as a potential bone substitute. Full article

Recent developments in sensing technologies have triggered a lot of research interest in exploring novel self-powered, inexpensive, compact and flexible pressure sensors with the potential for structural health monitoring (SHM) applications. Herein, we assessed the performance of an embedded mechanoluminescent (ML) and perovskite pressure sensor that integrates the physical principles of mechanoluminescence and perovskite materials. For a continuous in-situ SHM, it is crucial to evaluate the capabilities of the sensing device when embedded into a composite structure. An experimental study of how the sensor is affected by the embedment process into a glass fiber-reinforced composite has been conducted. A series of devices with and without ML were embedded within a composite laminate, and the signal responses were collected under different conditions. We also demonstrated a successful encapsulation process in order for the device to withstand the composite manufacturing conditions. The results show that the sensor exhibits distinct signals when subjected to different load conditions and can be used for the in-situ SHM of advanced composite structures. Full article

Taking into consideration the seismic vulnerability of older buildings and the increasing need for reducing their carbon footprint and energy consumption, the application of an innovative system is investigated; the system is based on the use of textile-reinforced mortar (TRM) and thermal insulation as a means of combined seismic and energy retrofitting of existing masonry walls. Medium-scale tests were carried out on masonry walls subjected to out-of-plane cyclic loading. The following parameters were investigated experimentally: placement of the TRM in a sandwich form (over and under the insulation) or outside the insulation, one-sided or two-sided TRM jacketing and/or insulation, and the displacement amplitude of the loading cycles. A simple analytical method is developed and found in good agreement with the test results. Additionally, numerical modeling is carried out and also found in good agreement with the test results. From the results obtained in this study, the authors believe that TRM jacketing may be combined effectively with thermal insulation, increasing the overall strength and energy efficiency of the masonry panels in buildings. Full article

Through-Thickness Reinforcement (TTR) technologies are well suited to improving the mechanical properties in the out-of-plane direction of fibre-reinforced composites. However, besides the enhancement of delamination resistance and thus the prevention of overall catastrophic failure, the presence of additional reinforcement elements in the composite structure affects also the mechanical properties in in-plane direction. In this work, the flexural behaviour of a glass-polypropylene (GF/PP) hybrid yarn-based composite with TTR in form of metallic pins has been investigated experimentally and numerically. The insertion of the metallic pins is realized via thermoactivated pinning technology (TAP). In four-point-bending tests, it is shown that the flexural stiffness and strength decreases with an increase of the overall pin density. Hereby, it is observed that the pins act as crack initiators. For numerical modelling on specimen level, a continuum damage mechanic (CDM) model is used to predict the nonlinear deformation response of the composite, as well as fibre fracture and matrix cracking. A debonding and slipping phenomena of the pin in the composite is modelled by a cohesive zone modelling approach for the interface between pin and composite. Full article

Fibre-reinforced polymer (FRP) rebar and geopolymer concrete (GPC) are relatively new construction materials that are now been increasingly used in the construction sectors. Both materials exhibit superior structural and durability properties that also make them a sustainable alternative solution. Due to the absence of any design standard for an FRP-reinforced GPC beam, it is important to validate the efficacy of available standards and literature related to other materials, e.g., FRP-reinforced conventional concrete or GPC alone. Four theories/design standards are considered for this comparison—ACI440.1R-15, CAN/CSA S806-12, parabolic stress block theory, and equivalent rectangular stress block theory for GPC under compression. The accuracy of these four approaches is also examined by studying the flexural performance of both the glass FRP (GFRP) and carbon FRP (CFRP). The FRP-reinforced beams are designed against the actual load they will be subjected to in a real-world scenario. It is concluded that parabolic stress block theory over-estimates the capacity, whereas CSA S806-12 yields the most accurate and conservative results. In addition, the flexural performance of the FRP-reinforced beams is evaluated in terms of ultimate, cracking, and service moment capacity, along with serviceable, ultimate, and residual deflection. Full article

Cellulose nanocrystal (CNC) is a nanoscale colloid with superior potential for coatings, liquid crystal displays, and optoelectronics. However, to date, the presence of hydrophilicity still limits its application. Multifunction via graft copolymerization modification of CNC appears to be breaking into a new direction. In this study, we used the residual hydroxyl groups on the CNC to react with 2-bromoisobu-tyryl bromide, and the initiator was therefore anchored on the CNC surface. Through atom transfer radical polymerization (ATRP), CNC was successfully grafted to azobenzene monomer, i.e., 9-[4-[2-[4-(trifluorometh) phenyl] diazenyl] phenoxy] nonayl acrylate (FAZO). After a series of characterization methods, such as FTIR, NMR and XRD, it was found that the surface water contact angle of the CNC-PFAZO prepared by the modification was as high as 134.4°, and the high hydrophilicity of this material could be maintained for up to one month, even longer. Full article

This paper deals with detection of macro-level crack type damage in rectangular E-Glass fiber/Epoxy resin (LY556) laminated composite plates using modal analysis. Composite plate-like structures are widely found in aerospace and automotive structural applications which are susceptible to damages. The formation of cracks in a structure that undergoes vibration may lead to catastrophic events such as structural failure, thus detection of such occurrences is considered necessary. In this research, a novel technique called as node-releasing technique in Finite Element Analysis (FEA), which was not attempted by the earlier researchers, is used to model the perpendicular cracks (the type of damage mostly considered in all the pioneering research works) and also slant cracks (a new type of damage considered in the present work) of various depths and lengths for Unidirectional Laminate (UDL) (${\left[0\right]}_{\mathrm{S}}$ and ${\left[45\right]}_{\mathrm{S}}$) composite layered configurations using commercial FE code Ansys, thus simulating the actual damage scenario. Another novelty of the present work is that the crack is modeled with partial depth along the thickness of the plate, instead of the through the thickness crack which has been of major focus in the literature so far, in order to include the possibility of existence of the crack up to certain layers in the laminated composite structures. The experimental modal analysis is carried out to validate the numerical model. Using central difference approximation method, the modal curvature is determined from the displacement mode shapes which are obtained via finite element analysis. The damage indicators investigated in this paper are Normalized Curvature Damage Factor (NCDF) and modal strain energy-based methods such as Strain Energy Difference (SED) and Damage Index (DI). It is concluded that, all the three damage detection algorithms detect the transverse crack clearly. In addition, the damage indicator NCDF seems to be more effective than the other two, particularly when the detection is for damage inclined to the longitudinal axis of the plate. The proposed method will provide the base data for implementing online structural health monitoring of structures using technologies such as Machine Learning, Artificial Intelligence, etc. Full article

Sodium-ion batteries (SIBs) have attracted increasing attention for storing renewable clean energy, owing to their cost-effectiveness. Nonetheless, SIBs still remain significant challenges in terms of the availability of suitable anode materials with high capacities and good rate capabilities. Our previous work has developed and verified that Cu₂S wrapped by nitrogen-doped graphene (i.e., Cu₂S@NG composite), as an anode in SIBs, could exhibit a superior performance with ultralong cyclability and excellent rate capability, mainly due to the multifunctional roles of NG. However, the Cu₂S@NG anode still suffers from continuous parasitic reactions at low potentials, causing a rapid performance deterioration. In this study, we investigated the effects of a conformal Al₂O₃ coating via atomic layer deposition (ALD) on the interfacial stability of the Cu₂S@NG anode. As a consequence, the ALD-coated Cu₂S@NG electrode can deliver a high capacity of 374 mAh g⁻¹ at a current density of 100 mA g⁻¹ and achieve a capacity retention of ~100% at different rates. This work verified that surface modification via ALD is a viable route for improving SIBs’ performances. Full article

This paper presents a damage-based failure criterion and its implementation in order to predict failure in ceramic matrix composites (CMC) manufactured via filament winding. The material behavior of CMCs is anisotropic and strongly depends on the angle between fiber orientation and loading direction. The inelastic behavior of laminates with different fiber orientations under tension and shear is modeled with the help of continuum damage mechanics. The parameters required for the damage model are obtained from a standard tensile and shear test. An isotropic damage law determines the evolution of damage in thermodynamic space and considers the interaction of damage parameters in different principal material directions. A quadratic damage-based failure criterion inspired by the Tsai-Wu failure criterion is proposed. Failure stress and strain can be predicted with higher accuracy compared to the Tsai-Wu failure criterion in stress- or strain-space. The use of the proposed damage limits allows designing a CMC component based on the microstructural phenomenon of stiffness loss. With the help of results obtained from modeling and experiments, fracture mechanics during the Iosipescu-shear test of CMCs and its capability to determine the shear strength of the material is discussed. Full article

In the paper, the bond between a composite strengthening system consisting of steel textiles embedded into an inorganic matrix (steel reinforced grout, SRG) and the concrete substrate, is investigated. An experimental investigation was carried out on medium density SRG specimens; direct shear tests were conducted on 20 specimens to analyze the effect of the bond length, and the age of the composite strip on the SRG-to-concrete bond behavior. In particular, the tests were conducted considering five bond length (100, 200, 250, 330, and 450 mm), and the composite strip’s age 14th, 21st, and 28th day after the bonding. Test results in the form of peak load, failure modes and, bond-slip diagrams were presented and discussed. A finite element model developed through commercial software to replicate the behavior of SRG strips, is also proposed. The effectiveness of the proposed numerical model was validated by the comparison between its predictions and experimental results. Full article

The benefit of using a combination of alkali pre-treatment and ball milling in processing hardwood particles into biocomposites via equal channel angular pressing (ECAP) was demonstrated. The penetration of bonding additives (polyethyleneimine and tannic acid) into hardwood structures was enhanced by the pre-treatment, resulting in plasticization and cross-linking derived from the additives during the particle processing. A significant improvement in the biocomposites’ mechanical properties was obtained, reaching flexural strength of 28–29 MPa and flexural modulus of 3650 MPa, comparable to those displayed by commercial wood fiberboard using thermosetting resins as the binding agent. This adds to the promise of developing biocomposites from industrial or agricultural waste through the simple and efficient ECAP technology in conjunction with common pre-treatment methodologies for wood particles. Full article

At present, the rapid accumulation of heat and the heat dissipation of electronic equipment and related components are important reasons that restrict the miniaturization, high integration, and high power of electronic equipment. It seriously affects the performance and life of electronic devices. Hence, improving the thermal conductivity of polymer composites (TCPCs) is the key to solving this problem. Compared with manufacturing intrinsic thermally conductive polymer composites, the method of filling the polymer matrix with thermally conductive fillers can better-enhance the thermal conductivity (λ) of the composites. This review starts from the thermal conduction mechanism and describes the factors affecting the λ of polymer composites, including filler type, filler morphology and distribution, and the functional surface treatment of fillers. Next, we introduce the preparation methods of filled thermally conductive polymer composites with different filler types. In addition, some commonly used thermal-conductivity theoretical models have been introduced to better-analyze the thermophysical properties of polymer composites. We discuss the simulation of λ and the thermal conduction process of polymer composites based on molecular dynamics and finite element analysis methods. Meanwhile, we briefly introduce the application of polymer composites in thermal management. Finally, we outline the challenges and prospects of TCPCs. Full article

The mechanical properties of the material are essential to identify the material behavior of the structure. Predicting four-directional braided composites’ mechanical properties based on accurate modeling is an essential issue among researchers. In this research, the principle of minimum energy loss-based mechanics of structure genome was used for the two-step homogenization of three-dimensional (3D) four-directional braided composites. In the first step homogenization, the micro-scale model’s effective mechanical properties were decided by considering fibers and matrix; in the second step homogenization, the final effective mechanical properties of the meso-scale model were obtained by considering yarns and matrix. TexGen python script was implemented for accurate modeling of 3D four-directional braided cells with jamming effects. The current process sustainability was validated for 3D four-directional braided polymer matrix composites (PMCs) material by available finite element analysis (FEA) and experimental literature. The method is further extended for 3D four-directional braided ceramic matrix composites (CMCs) to confirm its versatility for standard composites. A commercial FEA was also performed on the meso-scale braided cell to validate the two-step homogenization results. This research explored fast and more accurate modeling and analysis techniques for 3D four-directional braided composites. Full article

The performance of heterogeneous materials, for example, woven composites, does not always reach the predicted theoretical potential. This is caused by defects, such as residual voids introduced during the manufacturing process. A machine learning-based methodology is proposed to determine the morphology and spatial distribution of defects in composites based on X-ray microtomographic scans of the microstructure. A concept of defect "genome" is introduced as an indicator of the overall state of defects in the material, enabling a quick comparison of specimens manufactured under different conditions. The approach is illustrated for thermoplastic composites with unidirectional banana fiber reinforcement. Full article

The addition of fillers or reinforcements has a direct influence on the mechanical and electrical properties of polymers. Such properties are a function of the morphology and the distribution of fillers in the polymer base. Each feature may have contrasting effects on mechanical and electrical properties. In this study, chopped carbon fiber of different lengths and multiwalled carbon nanotubes (MWCNTs) were added to nylon 6,6. Specimens were manufactured by injection molding of a polyamide/MWCNT masterbatch with the addition of loose chopped carbon fiber. Tensile testing of dogbone specimens was conducted to obtain Young’s modulus, ultimate tensile strength, and elongation. Electrical conductivity testing was conducted on the same specimens prior to mechanical testing. To evaluate the morphology of fillers, scanning electron micrographs were evaluated. Micrographs show the presence of a skin layer close to the surface of the specimens. For this reason, core and surface conductivities were compared. The results show that while promising electrical properties can be achieved by the addition of fillers, the improvement in mechanical properties is minimal. Full article

The ballistic capabilities of composite metal foam (CMF) armors were experimentally tested against a 14.5 × 114 mm B32 armor-piercing incendiary (API) and compared to various sizes of armor-piercing (AP) ballistic threats, ranging from a 7.62 to 12.7 mm. Three different arrangements of layered hard armors were designed and manufactured using ceramic faceplates (in one layer, two layers or multiple tiles), a combination of ceramic and steel face sheets, with a single-layered CMF core, and a thin aluminum backing. The performance of various CMF armor designs against the 14.5 mm rounds are compared to each other and to the performance of the rolled homogeneous armor standard to identify the most efficient design for further investigations. The percentage of kinetic energy absorbed by the CMF layer in various armor arrangements and in tests against various threat sizes was calculated and compared. It appears that the larger the threat size, the more efficient the CMF layer will be due to a greater number of hollow metal spheres that are engaged in absorbing the impact energy. The results from this study will help to model and predict the performance of CMF armors against various threat sizes and impact energies. Full article

Poly(vinyl alcohol) (PVA) is a thermoplastic synthetic polymer, which, unlike many synthetic polymers, is not obtained by polymerization, but by hydrolysis of poly(vinyl acetate) (PVAc). Due to the presence of hydroxylic groups, hydrophilic polymers such as PVA and its composites made mainly with biopolymers are used for producing hydrogels that possess interesting morphological and physico-mechanical features. PVA hydrogels and other PVA composites are studied in light of their numerous application for electrical film membranes for chemical separation, element and dye removal, adsorption of metal ions, fuel cells, and packaging. Aside from applications in the engineering field, PVA, like other synthetic polymers, has applications in medicine and biological areas and has become one of the principal objectives of the researchers in the polymer domain. The review presents a few recent applications of PVA composites and contributions related to tissue engineering (repair and regeneration), drug carriers, and wound healing. Full article

This work focuses on flexible epoxy (EP) composites containing various amounts of neat and polydopamine (PDA)-coated paraffin microcapsules as a phase change material (PCM), which have potential applications as adhesives or flexible interfaces with thermal management capability for electronics or other high-value-added fields. After PDA modification, the surface of PDA-coated capsules (MC-PDA) becomes rough with a globular appearance, and the PDA layer enhances the adhesion with the surrounding epoxy matrix, as shown by scanning electron microscopy. PDA deposition parameters have been successfully tuned to obtain a PDA layer with a thickness of 53 ± 8 nm, and the total PDA mass in MC-PDA is only 2.2 wt %, considerably lower than previous results. This accounts for the fact that the phase change enthalpy of MC-PDA is only marginally lower than that of neat microcapsules (MC), being 221.1 J/g and 227.7 J/g, respectively. Differential scanning calorimetry shows that the phase change enthalpy of the prepared composites increases with the capsule content (up to 87.8 J/g) and that the enthalpy of the composites containing MC-PDA is comparable to that of the composites with MC. Dynamic mechanical analysis evidences a decreasing step in the storage modulus of all composites at the glass transition of the EP phase, but no additional signals are detected at the PCM melting. PCM addition positively contributes to the storage modulus both at room temperature and above $T_g$ of the EP phase, and this effect is more evident for composites containing MC-PDA. As the capsule content increases, the mechanical properties of the host EP matrix also increase in terms of elastic modulus (up to +195%), tensile strength (up to +42%), Shore D hardness (up to +36%), and creep compliance (down to −54% at 60 min). These effects are more evident for composites containing MC-PDA due to the enhanced interfacial adhesion. Full article

Degradation of the mechanical properties of fiber-reinforced polymer matrix composites (PMCs) subjected to cyclic loading is crucial to the long-term load-carrying capability of PMC structures in practice. This paper reports the experimental study of fatigue residual tensile strength and its probabilistic distribution in a carbon fiber-reinforced PMC laminate made of unidirectional (UD) carbon-fiber/epoxy prepregs (Hexcel T2G190/F263) with the ply layup [0/±45/90]_S after certain cycles of cyclic loading. The residual tensile strengths of the PMC laminates after cyclic loading of 1 (quasistatic), 2000, and 10,000 cycles were determined. Statistical analysis of the experimental data shows that the fatigue residual tensile strength of the PMC laminate follows a two-parameter Weibull distribution model with the credibility ≥ 95%. With increasing fatigue cycles, the mean value of the fatigue residual strength of the PMC specimens decreased while its deviation increased. A free-edge stress model is further adopted to explain the fatigue failure initiation of the composite laminate. The present experimental study is valuable for understanding the fatigue durability of PMC laminates as well as reliable design and performance prediction of composite structures. Full article

This work concerns a multiscale analysis of nano-reinforced heterogeneous materials. Such materials exhibit surface effects that must be taken into account in the homogenization procedure. In this study, a coherent imperfect interface model was employed to characterize the jumps of mechanical properties through the interface region between the matrix and the nanofillers. As the hypothesis of scale separation was adopted, a generalized self-consistent micromechanical scheme was employed for the determination of the homogenized elastic moduli. An explicit calculation for the determination of effective shear modulus is presented, together with a numerical application illustrating the surface effect. It is shown that the coherent imperfect interface model is capable of exploring the surface effect in nano-reinforced materials, as demonstrated experimentally in the literature. Full article

Alkali–silica reaction (ASR) attack is one of the most significant durability concerns in cement-based materials. In this paper, the drinking water treatment sludge (DWTS), which is a typical by-product from the drinking water treatment industry, was reused as supplementary cementitious material to mitigate the degradation of mortar resulting from ASR attack. DWTS was milled and calcined at 800 °C for 2 h before being used as a replacement for cement. Glass sand was used as the reactive fine aggregate. Properties of four mortar mixtures prepared with 0%, 5%, 10%, and 20% of calcined DWTS replacement of cement were firstly assessed, including compressive strength, flexural strength, and water sorptivity. The mortar specimens were then exposed to an ASR-attacked environment for 28 days, the changes in specimen length were monitored, and the uniformity of mortar was measured via Ultrasonic pulse velocity (UPV). The results showed that 10% replacement significantly improved the mechanical properties of mortar. The specimens with 20% of the calcined DWTS exhibited comparable strength relative to the reference group and exhibited superior resistance to ASR attack. Additionally, a water sorptivity test showed that higher contents of the calcined DWTS can lead to lower water capillary absorption of mortar. Full article

In order to build predictive analytic for engineering materials, large data is required for machine learning (ML). Gathering such a data can be demanding due to the challenges involved in producing specialty specimen and conducting ample experiments. Additionally, numerical simulations require efforts. Smaller datasets are still viable, however, they need to be boosted systematically for ML. A newly developed, knowledge-based data boosting (KBDB) process, named COMPOSITES, helps in logically enhancing the dataset size without further experimentation or detailed simulation. This process and its successful usage are discussed in this paper, using a combination of mode-I and mode-II inter-ply fracture toughness (IPFT) data on carbon nanotube (CNT) engineered carbon fiber reinforced polymer (CFRP) composites. The amount of CNT added to strengthen the mid-ply interface of CFRP vs the improvement in IPFT is studied. A simpler way of combining mode-I and mode-II values of IPFT to predict delamination resistance is presented. Every step of the 10-step KBDB process, its significance and implementation are explained and the results presented. The KBDB helped in not only adding a number of data points reliably, but also in finding boundaries and limitations of the augmented dataset. Such an authentically boosted dataset is vital for successful ML. Full article

This research aimed to fabricate lightweight and high-strength carbon nanotube (CNT)/aluminum (Al) composites by powder metallurgical and repeated hot-rolling techniques. The fabrication was conducted in three steps: (1) CNT dispersion, (2) preparation of CNT/Al compacts by powder metallurgical slurry methods, and (3) strengthening and refining of CNT/Al composites by repeated hot rolling. The processes of dispersion of CNTs were carried out with dimethylacetamide as a solvent and potassium carbonate as a dispersing agent, which is an inorganic salt, under ultrasonic sonication conditions. Effect of sonication time on dispersion states and mechanical properties was also examined. Full article

A high temperature epoxy resin was formulated by using a rosin-sourced anhydride-type curing agent, i.e., maleopimaric acid (RAM), and a two-component epoxy consisting of an E51-type epoxy and a solid phenolic epoxy to form a bio-sourced green matrix resin. The glass transition temperature of the final resin was 238 °C Carbon fiber composite prepreg and was manufactured and laminated into composite specimens. Interleaving Toughening Technology (ITT) was applied to the laminates by using Polyamide interleaf veils. The interlaminar fracture toughness and compression after impact (CAI) strength were investigated and showed that the opening Mode I interlaminar fracture toughness GIC and the Mode II interlaminar fracture toughness GIIC of the specimens with interleaves were significantly improved from 227.51 J/m² to 509.22 J/m² and 1064.3 J/m² to 1510.8 J/m², respectively. Correspondingly, the drop-weight impact test shows that the interleaves reduced the impact damage area from 20.9% to 11.3% of the total area, and the CAI residual strength was increased from 144 MPa to 191 MPa. Meanwhile, mechanical tests showed that the in-plane properties of the interleaved laminates were slightly reduced due to carbon fiber volume fraction reduction. In conclusion, the high glass transition temperature, fracture toughness and CAI behaviour make the green resin matrix composite a potential candidate for aerospace applications. Full article

Waste lignocellulose materials, such as brewers’ spent grain, can be considered very promising sources of fillers for the manufacturing of natural fiber composites. Nevertheless, due to the chemical structure differences between polymer matrices and brewers’ spent grain, filler treatment should be included. The presented work aimed to investigate the impact of fillers’ reactive extrusion on the chemical structure and the poly(ε-caprolactone)/brewers’ spent grain composites’ mechanical performance. The chemical structure was analyzed by Fourier-transform infrared spectroscopy, while the mechanical performance of composites was assessed by static tensile tests and dynamic mechanical analysis. Depending on the filler pretreatment, composites with different mechanical properties were obtained. Nevertheless, the increase in pretreatment temperature resulted in the increased interface surface area of filler, which enhanced composites’ toughness. As a result, composites were able to withstand a higher amount of stress before failure. The mechanical tests also indicated a drop in the adhesion factor, pointing to enhanced interfacial interactions for higher pretreatment temperatures. The presented work showed that reactive extrusion could be considered an auspicious method for lignocellulose filler modification, which could be tailored to obtain composites with desired properties. Full article

Recent studies have demonstrated that carbon nanomaterials have huge potential in composite applications, but there is a continuous quest for identifying the most viable technique for producing this material. In this study, the possibility of using an innovative approach for the synthesis of value-added carbon nanomaterials and green gases from end-of-life soft mattress materials (latex) was investigated. Thermogravimetric analysis (TGA) was used to determine the thermal degradation of latex. Quantitative gas analysis at three different temperatures by infrared spectroscopy (IR) suggested that small gas molecules, especially CH₄, could be produced at a higher temperature. The carbon residues produced after gas analysis were characterised by XRD, SEM, TEM, XPS, and Raman spectroscopy, suggesting the possibility of direct synthesis of carbon nanomaterials from waste latex. These carbon materials have Na, Zn, Si, and K in their structure, and further study is needed for understanding the effect of these elements on composite properties. Our study demonstrated that heat treatment of waste latex at 1000 °C for 15 min produced carbon materials, which contained 7–16% S and 1.2–2% N, and gases, such as CH₄, could be synthesised. Full article

The use of discontinuous fiber reinforced composites in injection and compression molding faces a number of challenges regarding process-induced changes in microstructure, which have a significant influence on the mechanical properties of the final component. The changes in final microstructure are caused by complex fiber movements, such as fiber orientation, attrition and accumulation during flow. While there are existing phenomenological prediction models for both fiber orientation and attrition, the prediction of fiber accumulation due to fiber-matrix separation is currently only possible with a complex mechanistic particle simulation, which is not applicable in industrial simulations. A simplified phenomenological model, the fiber retardation model (FRM), for the prediction of fiber-matrix separation in commercially available software tools is presented in this paper. The model applies a force balance onto an interacting two phase flow of polymer melt and fiber phase and applies a retardation factor Κ to calculate the slowing and accumulation of the fiber phase. The general model is successfully applied to a simple compression molding simulation. Full article

Discontinuous fiber composites (DFC) such as carbon fiber sheet molding compounds (CF-SMC) are increasingly used in the automotive industry for manufacturing lightweight parts. Due to the flow conditions during compression molding of complex geometries, a locally varying fiber orientation evolves. Knowing these process-induced fiber orientations is key to a proper part design since the mechanical properties of the final part highly depend on its local microstructure. Local fiber orientations can be measured and analyzed by means of micro-computed tomography (µCT) and digital image processing, or predicted by process simulation. This paper presents a detailed comparison of numerical and experimental analyses of compression molded ribbed hat profile parts made of CF-SMC with 50 mm long randomly oriented strands (ROS) of chopped unidirectional (UD) carbon/epoxy prepreg tape. X-ray µCT scans of three entire CF-SMC parts are analyzed to compare determined orientation tensors with those coming from a direct fiber simulation (DFS) tool featuring a novel strand generation approach, realistically mimicking the initial ROS charge mesostructure. The DFS results show an overall good agreement of predicted local fiber orientations with µCT measurements, and are therefore precious information that can be used in subsequent integrative simulations to determine the part’s mesostructure-related anisotropic behavior under mechanical loads. Full article

Short fiber reinforced thermoplastics (SFT) are extensively used due to their excellent mechanical properties and low processing costs. Long fiber reinforced thermoplastics (LFT) show an even more interesting property profile and are increasingly used for structural parts. However, their processing by injection molding is not as simple as for SFT, and their anisotropic properties resulting from the fiber microstructure (fiber orientation, length, and concentration) pose a challenge with regard to the engineering design process. To reliably predict the structural mechanical properties of fiber reinforced thermoplastics by means of micromechanical models, it is also necessary to reliable predict the fiber microstructure. Therefore, it is crucial to calibrate the underlying prediction models, such as the fiber orientation model, within the process simulation. In general, these models may be adjusted manually, but this is usually ineffective and time-consuming. To overcome this challenge, a new calibration method was developed to automatically calibrate the fiber orientation model parameters of the injection molding simulation by means of optimization methods. This optimization routine is based on experimentally determined fiber orientation distributions and leads to optimized parameters for the fiber orientation prediction model within a few minutes. To better understand the influence of the model parameters, different versions of the fiber orientation model, as well as process and material influences on the resulting fiber orientation distribution, were investigated. Finally, the developed approach to calibrate the fiber orientation model was compared with a classical approach, a direct optimization of the whole process simulation. Thereby, the new optimization approach shows a calculation time reduced by the factor 15 with comparable error variance. Full article

Composite materials are widely used in various manufacturing fields from aeronautic and aerospace industries to the automotive industry. This is due to their outstanding mechanical properties with respect to their light weight. However, some studies showed that the major flaws of these materials are located at the fiber/matrix interface. Therefore, enhancing matrix adhesion properties could significantly improve the overall material characteristics. This study aims to analyze the effect of graphene particles on the adhesion properties of carbon fiber-reinforced polymer (CFRP) through interlaminar shear strength (ILSS) and flexural testing. Seven modified epoxy resins were prepared with different graphene contents. The CFRP laminates were next manufactured using a method that guarantees a repeatable and consistent fiber volume fraction with a low porosity level. Short beam shear and flexural tests were performed to compare the effect of graphene on the mechanical properties of the different laminates. It was found that 0.25 wt.% of graphene filler enhanced the flexural strength by 5%, whilst the higher concentrations (2 and 3 wt.%) decreased the flexural strength by about 7%. Regarding the ILSS, samples with low concentrations (0.25 and 0.5 wt.%) demonstrated a decent increase. Meanwhile, 3 wt.% slightly decreases the ILSS. Full article