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J. Compos. Sci.
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Carbon Fiber Composites, 4th Edition
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Carbon Fiber Composites, 4th Edition

A special issue of Journal of Composites Science (ISSN 2504-477X). This special issue belongs to the section "Carbon Composites".

Deadline for manuscript submissions: 31 January 2026 | Viewed by 5192

Special Issue Editors

Dr. Jiadeng Zhu

E-Mail Website
Guest Editor
Brewer Science Inc., Springfield, MO 65806, USA
Interests: energy; polymers; fibers; biomaterials; low-dimensional materials
Special Issues, Collections and Topics in MDPI journals
Dr. Hyunjin Cho

E-Mail Website
Guest Editor
Department of Materials and Parts of Secondary Battery, Jeonju Kijeon College, Jeonju, Republic of Korea
Interests: 1D-2D nanomaterials; carbon fibers; boron nitride nanotubes; energy; hydrogen

Special Issue Information

Dear Colleagues,

Many efforts have been made to create light-weight materials that maintain excellent physical and chemical properties, aiming at energy savings and property enhancement for aerospace, automotive, marine, and industrial applications over the past few decades. Among them, carbon fibers and their composites have attracted significant attention because of their unique properties, including high strength and modulus, novel dimensional stability, high surface area/volume ratios, low coefficient of thermal expansion, etc. Therefore, they have been widely applied in fields of energy storage, filtration, aircraft, etc., via advanced manufacturing technologies (i.e., wet/melt spinning, solution casting, 3D printing, etc.).

Processing–structure–property relationships of carbon fibers and their composites are crucial for their future applications in the fields of energy, engineering, and the environment. Various precursors and processing approaches have been studied to prepare carbon fibers and composites with specific structures to achieve excellent multifunctional properties, consisting of better mechanical, thermal, electrical, and barrier properties. However, to date, lowering the manufacturing cost and expanding their applications remain challenging.

The main aim of this Special Issue is to tackle the points mentioned above for the preparation, characterization, and properties of advanced carbon fibers and their composites to offer an insight into them, facilitating their practical applications in various fields.

Dr. Jiadeng Zhu
Dr. Hyunjin Cho
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Journal of Composites Science is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 1800 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • carbon fibers
  • carbon nanofibers
  • composites
  • filtration
  • energy
  • environment

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Published Papers (7 papers)

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22 pages, 6771 KB  
Article
Enhancing Through-Thickness Electrical Conductivity in Recycled Carbon Fiber-Reinforced Polymer Composites Using Machining Waste
by Denise Bellisario, Fabrizio Quadrini, Francesco Napolitano and Pietro Russo
J. Compos. Sci. 2025, 9(8), 451; https://doi.org/10.3390/jcs9080451 - 21 Aug 2025
Viewed by 537
Abstract
CFRP (carbon fiber-reinforced polymer) production in Europe is approximately 10,000 metric tons annually, and according to the UK authorities, approximately 35% of end-of-life CFRP waste is currently landfilled. The authors propose a novel recycling process for industrial CFRP waste particles to produce the [...] Read more.
CFRP (carbon fiber-reinforced polymer) production in Europe is approximately 10,000 metric tons annually, and according to the UK authorities, approximately 35% of end-of-life CFRP waste is currently landfilled. The authors propose a novel recycling process for industrial CFRP waste particles to produce the core of a sandwich CFRP panel through the direct molding method. Industrial CFRP powder from grinding operations was collected, sieved and molded into square panels with and without external skins of virgin CFRP prepreg. Thermogravimetric (TGA) and differential scanning calorimetry (DSC) analysis revealed thermal activation (~70 °C), indicating potential for reprocessing. This study proposes a novel recycling route that directly molds industrial CFRP grinding waste into the core of sandwich structures, with or without virgin CFRP prepreg skins. Key findings: thermal re-processability was confirmed through TGA and DSC, showing activation near 70 °C; electrical conductivity reached 0.045 S/cm through the thickness in sandwich panels, with recycled cores maintaining comparable conductivity (0.04 S/cm); mechanical performance was improved significantly with prepreg skins, as evidenced by three-point bending tests showing enhanced stiffness and strength. These results demonstrate the potential of recycled CFRP waste in multifunctional structural applications, supporting circular economy goals in composite materials engineering. Full article
(This article belongs to the Special Issue Carbon Fiber Composites, 4th Edition)
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19 pages, 3437 KB  
Article
Sustainable Acrylic Thermoplastic Composites via Vacuum-Assisted Resin Infusion Molding: Evaluation and Comparison of Fabrics and Recycled Non-Woven Carbon Fiber as Reinforcement
by Sara Taherinezhad Tayebi, Tommaso Pini, Bruno Caruso, Matteo Sambucci, Irene Bavasso, Fabrizio Sarasini, Jacopo Tirillò and Marco Valente
J. Compos. Sci. 2025, 9(8), 441; https://doi.org/10.3390/jcs9080441 - 17 Aug 2025
Viewed by 593
Abstract
Recently, environmental issues have compelled people worldwide to pursue sustainability and adopt circular economy practices across all engineering sectors, including polymer engineering and composite fabrication. A transition towards fabric-reinforced thermoplastics (FRTPs), a greener solution, has been recommended in recent years. On the other [...] Read more.
Recently, environmental issues have compelled people worldwide to pursue sustainability and adopt circular economy practices across all engineering sectors, including polymer engineering and composite fabrication. A transition towards fabric-reinforced thermoplastics (FRTPs), a greener solution, has been recommended in recent years. On the other hand, utilizing recovered reinforcing phases, such as recycled carbon fiber (rCF), has attracted tremendous attention. In this framework, the aim of this research is to investigate the performance of acrylic-based FRTPs (Elium® resin developed by Arkema). Woven virgin carbon fiber (vCF) and non-woven recycled carbon fiber (rCF) fabrics were used as reinforcement architectures for the fabrication of composites via resin infusion. The optimized formulation selected for the matrix showed flexural modulus and flexural strength of 5 GPa and 78 MPa, respectively. Composites prepared with woven vCF reached 36 GPa and 620 MPa values of flexural modulus and strength, respectively. The study of non-woven fabric is of particular interest, because the web is composed of recycled carbon fibers obtained from end-of-life (EoL) thermoset composite components. The results were promising; the flexural modulus reached 8 GPa, and the flexural strength was 113 MPa. Improvements are anticipated, especially in the parameters and conditions of the molding process. Full article
(This article belongs to the Special Issue Carbon Fiber Composites, 4th Edition)
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18 pages, 8702 KB  
Article
Oxidation Process and Morphological Degradation of Drilling Chips from Carbon Fiber-Reinforced Polymers
by Dora Kroisová, Stepanka Dvorackova, Martin Bilek, Josef Skrivanek, Anita Białkowska and Mohamed Bakar
J. Compos. Sci. 2025, 9(8), 410; https://doi.org/10.3390/jcs9080410 - 2 Aug 2025
Viewed by 606
Abstract
Carbon fiber (CF) and carbon fiber-reinforced polymers (CFRPs) are widely used in the aerospace, automotive, and energy sectors due to their high strength, stiffness, and low density. However, significant waste is generated during manufacturing and after the use of CFRPs. Traditional disposal methods [...] Read more.
Carbon fiber (CF) and carbon fiber-reinforced polymers (CFRPs) are widely used in the aerospace, automotive, and energy sectors due to their high strength, stiffness, and low density. However, significant waste is generated during manufacturing and after the use of CFRPs. Traditional disposal methods like landfilling and incineration are unsustainable. CFRP machining processes, such as drilling and milling, produce fine chips and dust that are difficult to recycle due to their heterogeneity and contamination. This study investigates the oxidation behavior of CFRP drilling waste from two types of materials (tube and plate) under oxidative (non-inert) conditions. Thermogravimetric analysis (TGA) was performed from 200 °C to 800 °C to assess weight loss related to polymer degradation and carbon fiber integrity. Scanning electron microscopy (SEM) was used to analyze morphological changes and fiber damage. The optimal range for removing the polymer matrix without significant fiber degradation has been identified as 500–600 °C. At temperatures above 700 °C, notable surface and internal fiber damage occurred, along with nanostructure formation, which may pose health and environmental risks. The results show that partial fiber recovery is possible under ambient conditions, and this must be considered regarding the harmful risks to the human body if submicron particles are inhaled. This research supports sustainable CFRP recycling and fire hazard mitigation. Full article
(This article belongs to the Special Issue Carbon Fiber Composites, 4th Edition)
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19 pages, 9059 KB  
Article
Machine Vision Framework for Real-Time Surface Yarn Alignment Defect Detection in Carbon-Fiber-Reinforced Polymer Preforms
by Lun Li, Shixuan Yao, Shenglei Xiao and Zhuoran Wang
J. Compos. Sci. 2025, 9(6), 295; https://doi.org/10.3390/jcs9060295 - 7 Jun 2025
Viewed by 959
Abstract
Carbon-fiber-reinforced polymer (CFRP) preforms are vital for high-performance composite structures, yet the real-time detection of surface yarn alignment defects is hindered by complex textures. This study introduces a novel machine vision framework to enable the precise, real-time identification of such defects in CFRP [...] Read more.
Carbon-fiber-reinforced polymer (CFRP) preforms are vital for high-performance composite structures, yet the real-time detection of surface yarn alignment defects is hindered by complex textures. This study introduces a novel machine vision framework to enable the precise, real-time identification of such defects in CFRP preforms. We proposed obtaining the frequency spectrum by removing the zero-frequency component from the projection curve of images of carbon fiber fabric, aiding in the identification of the cycle number for warp and weft yarns. A texture structure recognition method based on the artistic conception drawing (ACD) revert is applied to distinguishing the complex and diverse surface texture of the woven carbon fabric prepreg from potential surface defects. Based on the linear discriminant analysis for defect area threshold extraction, a defect boundary tracking algorithm rule was developed to achieve defect localization. Using over 1500 images captured from actual production lines to validate and compare the performance, the proposed method significantly outperforms the other inspection approaches, achieving a 97.02% recognition rate with a 0.38 s per image processing time. This research contributes new scientific insights into the correlation between yarn alignment anomalies and a machine-vision-based texture analysis in CFRP preforms, potentially advancing our fundamental understanding of the defect mechanisms in composite materials and enabling data-driven quality control in advanced manufacturing. Full article
(This article belongs to the Special Issue Carbon Fiber Composites, 4th Edition)
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16 pages, 3569 KB  
Article
Micromechanical Analyses on Three-Dimensional Response of Compressive Failure in Unidirectional CFRP
by Atsushi Kondo, Yutaro Watanabe, Wataru Mikami, Yutaka Iwahori, Eiichi Hara and Hisaya Katoh
J. Compos. Sci. 2025, 9(6), 265; https://doi.org/10.3390/jcs9060265 - 27 May 2025
Viewed by 599
Abstract
Significant reductions in the compressive strength of CFRP are attributed to a specific failure process, which is a combination of the compressive failure of fibers and the shear failure of the matrix. To further understand the mechanism of compressive failure, micromechanical numerical models [...] Read more.
Significant reductions in the compressive strength of CFRP are attributed to a specific failure process, which is a combination of the compressive failure of fibers and the shear failure of the matrix. To further understand the mechanism of compressive failure, micromechanical numerical models were developed to reproduce the three-dimensional response, consisting of contraction by the compressive load and in-plane and out-of-plane shear deformation due to the rigid rotation of broken fibers. The feasibility of the model was confirmed by comparing the numerical results to theoretical results. The validated models were used to investigate the failure response under not only compressive loading but also in combination with in-plane and out-of-plane shear loadings. The variation in fiber misalignments and the strength of fibers were considered. The numerical model reproduced the trend of results from experiments in previous studies, in which the compressive strength of CFRP decreased with the increase in fiber misalignment. Moreover, the present results reveal that the ratio of in-plane and out-of-plane shear loadings is an important factor for the compressive strength and direction of shear deformation induced by compressive loading. Full article
(This article belongs to the Special Issue Carbon Fiber Composites, 4th Edition)
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19 pages, 40454 KB  
Article
Shining a Light on Carbon-Reinforced Polymers: Mg/MgO and TiO2 Nanomodifications for Enhanced Optical Performance
by Lukas Haiden, Michael Feuchter, Andreas J. Brunner, Michel Barbezat, Amol Pansare, Bharath Ravindran, Velislava Terziyska and Gerald Pinter
J. Compos. Sci. 2025, 9(4), 187; https://doi.org/10.3390/jcs9040187 - 12 Apr 2025
Cited by 2 | Viewed by 663
Abstract
This study examines the intrinsic optical enhancements of carbon fiber-reinforced polymers (CFRPs) achieved through the integration of magnesium oxide (MgO) nanoparticles, as well as Mg/MgO and titanium dioxide (TiO2) thin films onto carbon fibers. Integration was performed by quasi-continuous electrophoretic deposition [...] Read more.
This study examines the intrinsic optical enhancements of carbon fiber-reinforced polymers (CFRPs) achieved through the integration of magnesium oxide (MgO) nanoparticles, as well as Mg/MgO and titanium dioxide (TiO2) thin films onto carbon fibers. Integration was performed by quasi-continuous electrophoretic deposition (EPD) and physical vapor deposition (PVD), respectively. Employing a customized electrophoretic cell, EPD facilitated uniform MgO nanoparticle deposition onto unsized carbon fibers, ensuring stable nanoparticle dispersion and precise fiber coating. As a result, the fibers exhibited increased ultraviolet (UV) reflectance, largely attributed to the optical properties of the protective MgO layer. In parallel, PVD enabled the deposition of Mg/MgO and TiO2 thin films with tailored thicknesses, providing precise control over key optical parameters such as reflectivity and interference effects. Mg/MgO coatings demonstrated high UV reflectivity, while TiO2 layers, with their varying refractive indices, generated vibrant colors in the visible (Vis) range through thickness-dependent light interference. Scanning electron microscopy (SEM) and atomic force microscopy (AFM) assessed the quality, thickness, and uniformity of these thin films, and UV/Vis spectroscopy confirmed the influence of deposition parameters on the resulting optical performance. Post-lamination analyses revealed that both EPD and PVD modifications significantly enhanced UV reflectivity and allowed for customizable color effects. This dual strategy underscores the potential of combining EPD and PVD to develop advanced CFRPs with superior UV resistance, decorative optical features, and improved environmental stability. Full article
(This article belongs to the Special Issue Carbon Fiber Composites, 4th Edition)
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18 pages, 6813 KB  
Article
Effects of Matrix Properties on the Interfacial Shear Strength Between Carbon Fiber and Various Thermoplastic Polymers, and Their Influence on the Mechanical Properties of Composites
by Kazuto Tanaka and Ryota Sakakibara
J. Compos. Sci. 2025, 9(4), 174; https://doi.org/10.3390/jcs9040174 - 2 Apr 2025
Viewed by 871
Abstract
Although fiber–matrix interfacial strengths, which affect the mechanical properties of fiber-reinforced plastics (FRPs), are considered to be determined by complex factors, few studies have systematically evaluated the relationship between the matrix properties and the fiber–matrix interfacial shear strength. In this study, the properties [...] Read more.
Although fiber–matrix interfacial strengths, which affect the mechanical properties of fiber-reinforced plastics (FRPs), are considered to be determined by complex factors, few studies have systematically evaluated the relationship between the matrix properties and the fiber–matrix interfacial shear strength. In this study, the properties of various thermoplastics were measured, and the matrix tightening stress that constricts the fiber was simulated using finite element method (FEM) analysis. The relationships between the fiber–matrix interfacial shear strength and the matrix properties were clarified. The mechanical properties of carbon fiber reinforced thermoplastic (CFRTP) laminates were also evaluated, and the relationships between the fiber–matrix interfacial shear strength and the mechanical properties of CFRTP laminates were examined. The fiber–matrix interfacial shear strength showed a positive correlation with the matrix tightening stress tightening the fiber in the radial direction, as well as with matrix density, tensile strength, modulus, and melting temperature, while a negative correlation was found with the coefficient of linear expansion of the matrix. A higher fiber–matrix interfacial shear strength can be achieved by using a matrix with higher density, even without direct evaluation of the fiber–matrix interfacial strength, as the fiber–matrix interfacial shear strength showed a strong positive correlation with matrix density. Furthermore, the mechanical properties of CFRTP laminates were enhanced when matrices with higher fiber–matrix interfacial shear strength were used. Full article
(This article belongs to the Special Issue Carbon Fiber Composites, 4th Edition)
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