Journal of Composites Science

Research

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17 pages, 2314 KB

Open AccessArticle

Process Optimization and Non-Destructive Evaluation of Micro-Voids in Submarine Composite Structures for Enhanced Mechanical Performance

by Woo-Suk Choi and Jong-Yong Park

J. Compos. Sci. 2025, 9(11), 631; https://doi.org/10.3390/jcs9110631 - 13 Nov 2025

Viewed by 824

Abstract

This study presents a systematic approach to enhancing the mechanical performance of composite materials for submarine applications by quantitatively evaluating and controlling internal micro-voids generated during the manufacturing process. Three non-destructive evaluation techniques—ultrasonic testing, optical microscopy, and micro-computed tomography (Micro-CT)—were employed to assess [...] Read more.

This study presents a systematic approach to enhancing the mechanical performance of composite materials for submarine applications by quantitatively evaluating and controlling internal micro-voids generated during the manufacturing process. Three non-destructive evaluation techniques—ultrasonic testing, optical microscopy, and micro-computed tomography (Micro-CT)—were employed to assess the void content in fiber-reinforced composite specimens fabricated under various processing conditions. Tensile and flexural strength tests were conducted to investigate the correlation between the void content and mechanical properties. Among the methods, ultrasonic testing exhibited the strongest negative correlation (correlation coefficient = −0.703), confirming its effectiveness as a representative non-destructive evaluation technique. Furthermore, the statistical design of experiments, including factorial design, steepest ascent method, and response surface methodology (RSM), identified defoamer concentration and mixing time as the most influential process parameters in void reduction. The optimal processing conditions were determined to be 0.049% defoamer and 232 min of mixing. Under these conditions, the void content was minimized, and the mechanical properties were significantly improved. These findings offer practical guidance for void control and non-destructive evaluation in large-scale composite structures, contributing to improved reliability in underwater structural applications. Full article

(This article belongs to the Special Issue Trends and Challenges in Developing and Processing Composite Materials)

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12 pages, 1276 KB

Open AccessArticle

Delving into Process–Microstructure–Property Relationships in Cast-Extruded Polylactic Acid/Talc Composite Films: Effect of Different Screw Designs

by Giulia Bernagozzi, Chiara Gnoffo, Rossella Arrigo and Alberto Frache

J. Compos. Sci. 2025, 9(9), 483; https://doi.org/10.3390/jcs9090483 - 4 Sep 2025

Cited by 1 | Viewed by 1720

Abstract

In the context of polymer-based composites, the knowledge of the correlations between the processing conditions, the microstructure, and the final properties is essential to tailor polymeric systems for specific applications. Specifically concerning the extrusion process, an accurate design of the screw profile allows [...] Read more.

In the context of polymer-based composites, the knowledge of the correlations between the processing conditions, the microstructure, and the final properties is essential to tailor polymeric systems for specific applications. Specifically concerning the extrusion process, an accurate design of the screw profile allows for achieving composites with modulable microstructures, according to the specific properties required by the intended application. In this work, films of polylactic acid-based composites with 5 wt.% of talc were obtained by means of a single-screw extruder equipped with a flat die and a calender unit. Three different screw profiles, namely a general-purpose compression screw, a screw with a reverse flow zone, and a barrier screw, were employed for the production of films. The ability of the screw profile in varying the degree of filler dispersion and distribution was assessed through morphological and rheological analyses, demonstrating that the barrier screw is more able in disaggregating the talc lamellae. Due to the achieved microstructures, films produced using this screw profile exhibited superior barrier properties, with a decrease of about 27% in the oxygen permeability as compared to unfilled PLA. However, a concurrent decrease in material ductility as compared to the other films was observed. Finally, the thermoformability of the composites was assessed; also in this case, trays with more precise edges and corners were obtained for the film formulated through the barrier screw. Full article

(This article belongs to the Special Issue Trends and Challenges in Developing and Processing Composite Materials)

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13 pages, 2748 KB

Open AccessArticle

Experimental Study of the Combined Use of Silver Nanoparticles and Graphene Oxide to Predict the Operational Properties of New Bactericidal Composite Materials

by Svetlana E. Dimitrieva, Andrey N. Timonin, Sergey A. Baskakov, Oksana A. Kuznetsova and Alexey V. Shkirin

J. Compos. Sci. 2025, 9(7), 315; https://doi.org/10.3390/jcs9070315 - 20 Jun 2025

Viewed by 1070

Abstract

The aim of combining agents with different antibacterial mechanisms of action is to achieve a combined effect, which could be either the sum of their individual effects or a synergistic effect greater than the sum of these individual contributions. Mathematically, it seems reasonable [...] Read more.

The aim of combining agents with different antibacterial mechanisms of action is to achieve a combined effect, which could be either the sum of their individual effects or a synergistic effect greater than the sum of these individual contributions. Mathematically, it seems reasonable to use the simple addition of agent efficacy coefficients to simplify calculations. However, this article examines the validity of this simplification in mathematical models by calculating individual and synergistic bactericidal effects using the “black box” model. All agents were characterized according to current laboratory practice. The relative antibacterial efficacy coefficients of silver nanoparticles in a colloid with chitosan succinate (nAg SCC HTZ) and graphene oxide nanoparticles (GO) were determined. In particular, the activity of silver colloid was found to be 0.29 times the bactericidal activity of erythromycin, while the activity of GO was 0.107 times the bactericidal activity of the same antibiotic against Pseudomonas aeruginosa. At the same time, all the agents demonstrated stable bacteriostatic activity and were well described by linear regression. Testing the combined effects of agents did not reveal any drug synergy. Thus, the effect of silver at a given dose, followed by the addition of GO at a bacteriostatic dose, yielded an unreliable response, different from that of the “silver–GO” system at the same simultaneous inhibition doses (p > 0.1). The data obtained can be used to develop novel combined composite materials with bactericidal properties and to predict their characteristics. Full article

(This article belongs to the Special Issue Trends and Challenges in Developing and Processing Composite Materials)

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14 pages, 5278 KB

Open AccessArticle

Microwave Synthesis of Luminescent Recycled Glass Containing Dy₂O₃ and Sm₂O₃

by Achanai Buasri, Apichaya Boonpanya, Arraya Yangderm, Thanaporn Kensopha and Vorrada Loryuenyong

J. Compos. Sci. 2025, 9(2), 64; https://doi.org/10.3390/jcs9020064 - 1 Feb 2025

Cited by 5 | Viewed by 2592

Abstract

This research studied the recycling of borosilicate glass wastes from damaged laboratory glassware. The luminescent glasses were prepared by doping glass waste powder with rare earth ions, namely, dysprosium ions (Dy³⁺) and samarium ions (Sm³⁺), as well as co-doping [...] Read more.

This research studied the recycling of borosilicate glass wastes from damaged laboratory glassware. The luminescent glasses were prepared by doping glass waste powder with rare earth ions, namely, dysprosium ions (Dy³⁺) and samarium ions (Sm³⁺), as well as co-doping with Dy³⁺ and Sm³⁺ at a concentration of 2% by weight. The sintering process was conducted in a microwave oven for a duration of 15 min. The photoluminescence spectra of the doped glasses were obtained under excitation at 401 nm and 388 nm. The results showed that the emission characteristics depended on the doping concentrations of Dy³⁺ and Sm³⁺ and the excitation wavelengths. Upon excitation at 401 nm, the co-doped glasses exhibited the maximum emission peak of Sm³⁺ at 601 nm (yellowish and orange region in the CIE chromaticity diagram) due to the energy transition from ⁴G_5/2 to ⁶H_7/2. When excited at 388 nm, however, the emission spectra of the co-doped glasses were similar to the characteristic emission peaks of Dy³⁺ (white region in the CIE chromaticity diagram), but the peak position exhibits a red shift. This could be attributed to an increase in the amount of non-bridging oxygens (NBOs) by co-doping. Full article

(This article belongs to the Special Issue Trends and Challenges in Developing and Processing Composite Materials)

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10 pages, 2602 KB

Open AccessArticle

Endothermic–Exothermic Hybrid Foaming of Recycled PET Blends

by Veronika Anna Szabó, Gusztáv Fekete and Gábor Dogossy

J. Compos. Sci. 2024, 8(10), 383; https://doi.org/10.3390/jcs8100383 - 24 Sep 2024

Cited by 4 | Viewed by 2038

Abstract

Over the past decades, the use of polyethylene terephthalate (PET) has seen significant growth, particularly in the packaging industry. However, its long decomposition time poses serious environmental challenges. The aim of this research was to develop a process for the foaming of large [...] Read more.

Over the past decades, the use of polyethylene terephthalate (PET) has seen significant growth, particularly in the packaging industry. However, its long decomposition time poses serious environmental challenges. The aim of this research was to develop a process for the foaming of large quantities of recycled PET (rPET) using endothermic and exothermic foaming agents. Various formulations with different ratios of endothermic and exothermic foaming agents were prepared, as well as their mixtures. The study found that the endothermic–exothermic hybrid foaming process resulted in a finer cell-size distribution and enhanced mechanical properties, making the foams highly suitable for widespread applications. The results support the potential use of exothermic foaming agents as nucleating agents in a hybrid foaming system. In particular, the ratio of 3% endothermic and 1% exothermic foaming agents proved optimal in terms of achieving a balance between porosity and mechanical strength, thereby enabling broad industrial applicability. Full article

(This article belongs to the Special Issue Trends and Challenges in Developing and Processing Composite Materials)

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Review

Jump to: Research

21 pages, 2890 KB

Open AccessReview

AI in Composite Overwrapped Pressure Vessels: A Review and Advanced Roadmap from Materials Design to Predictive Maintenance

by Lyazid Bouhala and Séverine Perbal

J. Compos. Sci. 2026, 10(3), 171; https://doi.org/10.3390/jcs10030171 - 23 Mar 2026

Viewed by 532

Abstract

The integration of Artificial Intelligence (AI) into the design, manufacturing, and lifecycle management of Composite Overwrapped Pressure Vessels (COPVs) is transforming the pathway toward autonomous and adaptive composite systems. This paper presents a comprehensive review and roadmap for AI-enabled COPVs development, bridging materials [...] Read more.

The integration of Artificial Intelligence (AI) into the design, manufacturing, and lifecycle management of Composite Overwrapped Pressure Vessels (COPVs) is transforming the pathway toward autonomous and adaptive composite systems. This paper presents a comprehensive review and roadmap for AI-enabled COPVs development, bridging materials design, process optimisation, and predictive maintenance. The study synthesises over a decade of research on data-driven composite manufacturing, combining technology intelligence, PESTEL-SWOT environmental assessment, and cross-sectoral analysis of industrial and academic advances. A unified workflow is proposed to illustrate AI integration across the COPVs lifecycle, highlighting data feedback loops for continuous optimisation through digital twins and intelligent process control. Structural Health Monitoring (SHM) plays a central role in this ecosystem by providing real-time high-fidelity data on damage evolution and environmental interactions in COPVs. Through embedded sensing technologies such as fibre optic sensors and acoustic emission systems, SHM enhances digital twin fidelity, supports AI-based anomaly detection, and strengthens model validation in safety-critical hydrogen storage applications. Critical challenges are identified, including limited hydrogen-exposure datasets, lack of real-time adaptability, explainability in safety-critical design, and sustainability of AI-intensive workflows. These challenges highlight the need for tighter SHM-AI integration to enable reliable condition assessment and prognostics under multi-physics loading conditions. Based on these findings, the paper outlines actionable research directions to enable reliable, transparent, and sustainable AI adoption in composite manufacturing under the Industry 4.0 and hydrogen-economy paradigms. Full article

(This article belongs to the Special Issue Trends and Challenges in Developing and Processing Composite Materials)

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23 pages, 2611 KB

Open AccessReview

Circular Approaches for Thermoset Composites

by Marta Camacho-Iglesias, Lorena Germán, Aitziber Iturmendi and Rubén Seoane-Rivero

J. Compos. Sci. 2025, 9(12), 682; https://doi.org/10.3390/jcs9120682 - 9 Dec 2025

Cited by 1 | Viewed by 1075

Abstract

The recycling and reuse of thermoset composite materials present considerable challenges due to the cross-linked network formed during the curing process. The growing implementation of these materials in various industries, such as automotive and wind energy sectors, has generated significant research interest in [...] Read more.

The recycling and reuse of thermoset composite materials present considerable challenges due to the cross-linked network formed during the curing process. The growing implementation of these materials in various industries, such as automotive and wind energy sectors, has generated significant research interest in this area. This paper presents a comprehensive review of different approaches for the recycling, focusing on two aspects: established methods with higher technological readiness levels (mechanical, thermal, and chemical) and emerging methods still under development (microwave-assisted recycling, enzymatic recycling, electrochemical recycling, superheated steam recycling and ultrasonic recycling). Furthermore, the reuse of thermoset composite materials by thermoforming, for example, is discussed, along with an overview of innovative resin systems specially designed for recyclability and reusability. Finally, the challenges and future prospects are briefly summarised. Full article

(This article belongs to the Special Issue Trends and Challenges in Developing and Processing Composite Materials)

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17 pages, 415 KB

Open AccessReview

Advanced Wood Composites with Recyclable or Biodegradable Polymers Embedded—A Review of Current Trends

by Paschalina Terzopoulou, Dimitris S. Achilias and Evangelia C. Vouvoudi

J. Compos. Sci. 2025, 9(8), 415; https://doi.org/10.3390/jcs9080415 - 4 Aug 2025

Cited by 3 | Viewed by 3023

Abstract

Wood polymer composites (WPCs) represent a rapidly growing class of sustainable materials, formed by combining lignocellulosic fibers with thermoplastic or thermoset polymeric matrices. This review summarizes the state of the art in WPC development, emphasizing the use of recyclable (or recycled) and biodegradable [...] Read more.

Wood polymer composites (WPCs) represent a rapidly growing class of sustainable materials, formed by combining lignocellulosic fibers with thermoplastic or thermoset polymeric matrices. This review summarizes the state of the art in WPC development, emphasizing the use of recyclable (or recycled) and biodegradable polymers as matrix materials. The integration of waste wood particles into the production of WPCs addresses global environmental challenges, including plastic pollution and deforestation, by offering an alternative to conventional wood-based and petroleum-based products. Key topics covered in the review include raw material sources, fiber pre-treatments, compatibilizers, mechanical performance, water absorption behavior, thermal stability and end-use applications. Full article

(This article belongs to the Special Issue Trends and Challenges in Developing and Processing Composite Materials)

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28 pages, 14294 KB

Open AccessReview

A Short Review on Radiopaque Polyurethanes in Medicine: Physical Principles, Effect of Nanoparticles, Processing, Properties, and Applications

by Julia Garavatti and Heitor Luiz Ornaghi Jr.

J. Compos. Sci. 2024, 8(10), 409; https://doi.org/10.3390/jcs8100409 - 5 Oct 2024

Cited by 3 | Viewed by 3842

Abstract

Polyurethanes are used in a wide range of biomedical applications due to their variety of physical–chemical, mechanical, and structural properties, and biotic and abiotic degradation. They are widely used in bio-imaging procedures when metallic-based filler particles are incorporated, making the final product radiopaque. [...] Read more.

Polyurethanes are used in a wide range of biomedical applications due to their variety of physical–chemical, mechanical, and structural properties, and biotic and abiotic degradation. They are widely used in bio-imaging procedures when metallic-based filler particles are incorporated, making the final product radiopaque. It would be advantageous, however, if polyurethanes with intrinsic radiopacity could be produced in their synthesis, avoiding a series of disadvantages in the processing and final product and also presenting potential antimicrobial activities. This review’s objective was to study the radiopacifying characteristics of nanoparticles, the physical principles of radiopacity, and the variety of medical applications of polyurethanes with nanoparticles. It was found in this study that the synthetization of radiopaque polyurethanes is not only possible but the efficiency of synthetization was improved when using atoms with high electron density as part of the backbone or when grafted, making them great multipurpose materials. Full article

(This article belongs to the Special Issue Trends and Challenges in Developing and Processing Composite Materials)

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