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J. Compos. Sci.
Special Issues
Advanced Composite Materials: Design, Implementation and Characterization
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Advanced Composite Materials: Design, Implementation and Characterization

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

Deadline for manuscript submissions: 31 December 2026 | Viewed by 7811

Special Issue Editor

Prof. Dr. Luigi Solazzi

E-Mail Website
Guest Editor
Department of Mechanical and Industrial Engineering, University of Brescia, Brescia, Italy
Interests: composite material; pressure vessel; design multilayer cylindrical components; experimental tests; applied composite material; dynamic load; load movement; impulse loading; structural vibration; dynamic behaviour; dynamic analyses; lifting equipment; crane; finite element analyses
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Currently, attaining economic and environmental sustainability is crucial. One methodology to achieve this is the utilization of innovative materials such as composites instead of, for example, classical structural steels.

In the literature, numerous studies focus on the theoretical aspects of composites. In this Special Issue, attention will be given not only to theoretical approaches but also to the implementation of such materials.

Our goals are to explore how composite materials can be used to enhance component performance and to evaluate their behavior and durability. This concerns developing specific testing methodologies and related equipment to characterize these materials and components.

This Special Issue will cover (but will not be limited to) the following topics:

  • the design of components made of composite materials;
  • static, fatigue, and fracture design;
  • damage criteria;
  • experimental tests characterizing both composite materials and components;
  • lightweight components;
  • joint design (regarding static, fatigue age effects, etc.);
  • manufacturing processes;
  • innovative and emerging applications of composite materials.

Prof. Dr. Luigi Solazzi
Guest Editor

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 250 words) can be sent to the Editorial Office for assessment.

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

  • lightweighting components
  • static, fatigue and fracture performance
  • manufacturing processes

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Further information on MDPI's Special Issue policies can be found here.

Published Papers (7 papers)

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Research

17 pages, 3276 KB  
Article
An Improved Compression-After-Low-Velocity-Impact Test Setup and Its Application to Thin Angle-Ply CFRP Laminates
by Marius Nicolae Baba
J. Compos. Sci. 2026, 10(3), 165; https://doi.org/10.3390/jcs10030165 - 18 Mar 2026
Viewed by 241
Abstract
Low-velocity impacts can cause barely visible impact damage (BVID) in carbon-fiber-reinforced polymer (CFRP) laminates, leading to significant reductions in residual compressive strength. Compression-after-impact (CAI) tests are therefore essential for damage-tolerance design, but existing fixtures often allow global buckling or edge crushing, which can [...] Read more.
Low-velocity impacts can cause barely visible impact damage (BVID) in carbon-fiber-reinforced polymer (CFRP) laminates, leading to significant reductions in residual compressive strength. Compression-after-impact (CAI) tests are therefore essential for damage-tolerance design, but existing fixtures often allow global buckling or edge crushing, which can compromise test accuracy. This study experimentally investigates the CAI response of two symmetric angle-ply CFRP laminates with reversed stacking sequences, [0/−45/45/90]s and [90/45/−45/0]s, using a modified CAI fixture. Compared to standard CAI rigs, the modified fixture combines the lateral guidance with anti-buckling plates that clamp the upper and lower specimen edges using a bolt–nut assembly, thereby reducing the active gauge length and stabilizing the panel during compression. Rectangular plate specimens were first impacted at low velocity with a hemispherical projectile; the BVID threshold was defined by a permanent indentation depth of 0.8 mm for [0/−45/45/90]s and 0.7 mm for [90/45/−45/0]s, measured 24 h after impact. Subsequent CAI tests showed about a 22% reduction in maximum compressive load at the BVID level for both layups, while the post-impact compressive stiffness decreased by 17% for [0/−45/45/90]s and 6% for [90/45/−45/0]s. These results demonstrate that reversing the symmetric layup significantly affects stiffness degradation and that the proposed CAI setup suppresses global buckling and edge-dominated failures in all testson the investigated thin CFRP laminates, enabling repeatable residual-strength and stiffness measurements. Full article
(This article belongs to the Special Issue Advanced Composite Materials: Design, Implementation and Characterization)
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33 pages, 5097 KB  
Article
Upcycling Pultruded Polyester–Glass Thermoset Scraps into Polyolefin Composites: A Comparative Structure–Property Insights
by Hasan Kasim, Yongzhe Yan, Haibin Ning and Selvum Brian Pillay
J. Compos. Sci. 2026, 10(1), 52; https://doi.org/10.3390/jcs10010052 - 16 Jan 2026
Viewed by 1186
Abstract
This study investigates the reuse of mechanically recycled polyester–glass thermoset scraps (PS) as fillers in LDPE and HDPE matrices at 10–50 wt.% loading. Composites were produced through mechanical size reduction, single-screw extrusion, and compression molding without compatibilizers, and their mechanical and microstructural properties [...] Read more.
This study investigates the reuse of mechanically recycled polyester–glass thermoset scraps (PS) as fillers in LDPE and HDPE matrices at 10–50 wt.% loading. Composites were produced through mechanical size reduction, single-screw extrusion, and compression molding without compatibilizers, and their mechanical and microstructural properties were systematically evaluated. LDPE composites exhibited a notable stiffness increase, with tensile modulus rising from 318.8 MPa (neat) to 1245.6 MPA (+291%) and tensile strength improving from 9.50 to 11.45 MPa (+20.5%). Flexural performance showed even stronger reinforcement: flexural modulus increased from 0.40 to 3.00 GPa (+650%) and flexural strength from 14.5 to 35.6 MPa (+145%). HDPE composites displayed similar behavior, with flexural modulus increasing from 1.2 to 3.1 GPa (+158%) and strength from 34.1 to 45.5 MPa (+33%). Surface-treated fillers provided additional stiffness gains (+36% in sPL4; +33% in sPH3). Impact strength decreased with loading (LDPE: −51%, HDPE: −61%), though surface treatment partially mitigated this (+14–19% in LDPE; +13% in HDPE). Density increased proportionally (PL: 0.95 → 1.20 g/cm3, PH: 0.99 → 1.23 g/cm3), while moisture uptake remained low (≤0.25%). Optical and SEM analyses indicated increasingly interconnected fiber networks at high loadings, driving stiffness and fracture behavior. Overall, PS-filled polyolefins offer a scalable route for converting thermoset waste into functional semi-structural materials. Full article
(This article belongs to the Special Issue Advanced Composite Materials: Design, Implementation and Characterization)
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17 pages, 4235 KB  
Article
Additive Manufacturing of Graphene Oxide/Sodium Alginate–Cotton Microfiber Composite Hydrogels: Structure, Properties, and Adsorption Performance
by Nickolly B. V. Serafim, Caroline M. B. de Araujo, Margarida S. C. A. Brito, Yaidelin A. Manrique, Cláudia G. Silva, Marcos G. Ghislandi, Jose L. Sanchez-Salvador, Angeles Blanco, Jorge V. F. L. Cavalcanti, Maurício A. da Motta Sobrinho and Alexandre F. P. Ferreira
J. Compos. Sci. 2025, 9(12), 673; https://doi.org/10.3390/jcs9120673 - 4 Dec 2025
Viewed by 1375
Abstract
The high use and improper disposal of chloroquine (CQ) during the COVID-19 pandemic have significantly increased its presence in water bodies, representing an environmental risk. Adsorption is one of the most-used treatments to remove recalcitrant compounds, although there is still a lack of [...] Read more.
The high use and improper disposal of chloroquine (CQ) during the COVID-19 pandemic have significantly increased its presence in water bodies, representing an environmental risk. Adsorption is one of the most-used treatments to remove recalcitrant compounds, although there is still a lack of efficient biosorbents. This work aimed to develop an efficient biosorbent using additive manufacturing (AM) to synthesize bionanocomposite hydrogels based on cellulose fibers, sodium alginate (SA), and graphene oxide (GO) for CQ adsorption. The hydrogels were characterized by mechanical, morphological, and physicochemical techniques. Results show that increasing GO content and reducing water contributed to higher yield stress, which is important for maintaining shape fidelity during the printing. SEM images evidenced thin GO layers interacting with the polymer matrix and cellulose fibers, resulting in 3D disordered porous microstructures. The adsorption capacity of the 3D-printed hydrogel samples for aqueous CQ was analyzed by evaluating the pH effect, contact time, and the adsorption equilibrium isotherms, showing notorious potential for CQ removal, with maximum adsorption capacity of ~25 mg∙g−1 at 25 °C. Results show that the tested formulations were stable for producing hydrogels and efficient on chloroquine adsorption, revealing their potential as novel adsorbents for removing emerging organic pollutants from water. Full article
(This article belongs to the Special Issue Advanced Composite Materials: Design, Implementation and Characterization)
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15 pages, 3287 KB  
Article
Preparation and Characterization of Polyethylene-Based Composites with Iron-Manganese “Core-Shell” Nanoparticles
by Gleb Yu. Yurkov, Alexander V. Kozinkin, Anna V. Maksimova, Valeriy G. Vlasenko, Stanislav P. Kubrin, Vladislav E. Kirillov and Vitaliy I. Solodilov
J. Compos. Sci. 2025, 9(12), 666; https://doi.org/10.3390/jcs9120666 - 3 Dec 2025
Viewed by 961
Abstract
Composite materials based on low-density polyethylene (LDPE) embedded with iron-manganese nanoparticles with compositions Fe0.9Mn0.1 and Fe0.8Mn0.2 were prepared and investigated. The newly created composites were characterized using transmission electron microscopy (TEM), X-ray diffraction (XRD), X-ray absorption near-edge [...] Read more.
Composite materials based on low-density polyethylene (LDPE) embedded with iron-manganese nanoparticles with compositions Fe0.9Mn0.1 and Fe0.8Mn0.2 were prepared and investigated. The newly created composites were characterized using transmission electron microscopy (TEM), X-ray diffraction (XRD), X-ray absorption near-edge structure (XANES), extended X-ray absorption fine structure (EXAFS), and Mössbauer spectroscopy. The composition, electronic, and atomic structure of the nanoparticles were established. The study confirms that the nanoparticles possess a ‘core-shell’ structure, the nature of which depends on the manganese content. The nanoparticles of Fe0.8Mn0.2 in LDPE exhibit a three-layered structure: a metallic α-Fe core is coated with an intermediate oxidized layer structurally close to Fe2O3, while the outermost shell consists of manganese oxide (Mn2O3). In contrast, nanoparticles with lower Mn content Fe0.9Mn0.1 show a predominantly fully oxidized structure. This structural evolution is consistent with thermodynamic principles, where manganese, having a higher oxide formation enthalpy, migrates to the surface. The core–shell architecture is promising for applications requiring stable magnetic components or tailored catalytic interfaces within a polymer matrix. Full article
(This article belongs to the Special Issue Advanced Composite Materials: Design, Implementation and Characterization)
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22 pages, 2042 KB  
Article
Implementation of Composite Materials for Lightweighting of Industrial Vehicle Chassis
by Ivan Tomasi, Stefano Grandi, Giorgio Donzella and Luigi Solazzi
J. Compos. Sci. 2025, 9(11), 611; https://doi.org/10.3390/jcs9110611 - 5 Nov 2025
Viewed by 1248
Abstract
This research study investigates the use of composite materials to reduce the weight of heavy industrial vehicle chassis. A new Carbon Fibre Reinforced Polymer (CFRP) crossmember was developed to replicate the mechanical performance of the traditional steel component while achieving substantial weight reduction. [...] Read more.
This research study investigates the use of composite materials to reduce the weight of heavy industrial vehicle chassis. A new Carbon Fibre Reinforced Polymer (CFRP) crossmember was developed to replicate the mechanical performance of the traditional steel component while achieving substantial weight reduction. A multi-step approach was adopted: analytical and finite-element analyses were performed on single crossmembers to assess bending and torsional stiffness. The CFRP design achieved increases of 6.8% in torsional stiffness and 5.0% in bending stiffness, with a 68.1% weight reduction. After confirming stiffness equivalence, full chassis simulations were carried out to evaluate global performance. The steel model reproduced experimental results with a relative error of 1.13%, while the CFRP configuration enhanced overall torsional stiffness by 7.8%. Extending these results to all crossmembers, the initial cost increase of the CFRP solution could be recovered within about 2 years for the diesel scenario and 3.5 years for the electric one. Environmental benefits were also quantified, with annual CO2 reductions of 708.4 kg and 298.6 kg, and cost savings of up to 463.3 EUR/year and 299.8 EUR/year, respectively. Full article
(This article belongs to the Special Issue Advanced Composite Materials: Design, Implementation and Characterization)
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15 pages, 3520 KB  
Article
Multi-Material Fused Filament Fabrication of TPU Composite Honeycombs Featuring Out-of-Plane Gradient Stiffness
by Savvas Koltsakidis, Konstantinos Tsongas, Nikolaos Papas, Eleftheria Maria Pechlivani and Dimitrios Tzetzis
J. Compos. Sci. 2025, 9(11), 588; https://doi.org/10.3390/jcs9110588 - 1 Nov 2025
Cited by 1 | Viewed by 1075
Abstract
Gradient stiffness structures are increasingly recognized for their excellent energy absorption capabilities, particularly under challenging loading conditions. Most studies focus on varying the thickness of the structure in order to produce gradient stiffness. This work introduces an innovative approach to design honeycomb architectures [...] Read more.
Gradient stiffness structures are increasingly recognized for their excellent energy absorption capabilities, particularly under challenging loading conditions. Most studies focus on varying the thickness of the structure in order to produce gradient stiffness. This work introduces an innovative approach to design honeycomb architectures with controlled gradient stiffness along the out-of-plane direction achieved by materials’ microstructure variations. The gradient is achieved by combining three types of thermoplastic polyurethane (TPU) materials: porous TPU, plain TPU, and carbon fiber (CF)-reinforced TPU. By varying the material distribution across the honeycomb layers, a smooth transition in stiffness is formed, improving both mechanical resilience and energy dissipation. To fabricate these structures, a dual-head 3D printer was employed with one head printed processed TPU with a chemical blowing agent to produce porous and plain sections, while the other printed a CF-reinforced TPU. By alternating between the two print heads and modifying the processing temperatures, honeycombs with up to three distinct stiffness zones were produced. Compression testing under out-of-plane loading revealed clear plateau and densification regions in the stress–strain curves. Pure CF-reinforced honeycombs absorbed the most energy at stress levels above ~4.5 MPa, while porous TPU honeycombs were more effective under stress levels below ~1 MPa. Importantly, the gradient stiffness honeycombs achieved a balanced energy absorption profile across a broader range of stress levels, offering enhanced performance and adaptability for applications like protective equipment, packaging, and automotive structures. Full article
(This article belongs to the Special Issue Advanced Composite Materials: Design, Implementation and Characterization)
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13 pages, 2047 KB  
Article
Study of the Relationship Between Microstructure, Phase Composition and Strength Characteristics in Composite Ceramics Based on ZrO2-Al2O3 System
by Rafael I. Shakirzyanov, Yuriy A. Garanin, Malik E. Kaliyekperov, Sofiya A. Maznykh and Dilnaz K. Zhamikhanova
J. Compos. Sci. 2025, 9(10), 519; https://doi.org/10.3390/jcs9100519 - 29 Sep 2025
Cited by 1 | Viewed by 1130
Abstract
ZrO2-MgO-Al2O3 ceramics, despite a long history of research, still attract the attention of researchers due to the high potential of their applications as refractories and matrices for metal ceramics. A unique composition combining high strength and temperature stability [...] Read more.
ZrO2-MgO-Al2O3 ceramics, despite a long history of research, still attract the attention of researchers due to the high potential of their applications as refractories and matrices for metal ceramics. A unique composition combining high strength and temperature stability is particularly in demand. In this paper, a comprehensive study of ceramics of the composition (90−x)·ZrO2-10·MgO-x·Al2O3 (x = 10–80 wt.%) obtained by solid-phase sintering with preliminary annealing is carried out. Preliminary annealing was used for the possible formation of metastable phases with outstanding mechanical properties. Using the X-ray diffraction method, it was found that most of the samples consist of monoclinic zirconium oxide, magnesium–aluminum spinel, and corundum phases. The exception is the sample with x = 10 wt.%, in which the main phase was a cubic modification of zirconium oxide. By formation this type of ZrO2 polymorph in the composition hardness and flexural strength significantly increased from 400 to 1380 and 50 to 210 MPa, respectively. The total porosity of ceramics under study lies in the range 6–28%. Using the scanning electron microscopy method, it was found that the phase composition significantly affects the morphology of the microstructure of the sintered bodies. Thus, for sintered ceramics with a high corundum content, the microstructure is characterized by high porosity and a large grain size. For the first time, by applying preliminary annealing, a new type of ternary ceramic ZrO2-MgO-Al2O3 was sintered with potentially outstanding mechanical properties. The presence of a stabilized zirconium oxide phase, stresses in the crystal lattice of the matrix phase, and the formation of cracks in the microstructure are the main factors influencing shrinkage, porosity, microhardness, and biaxial flexural strength. Full article
(This article belongs to the Special Issue Advanced Composite Materials: Design, Implementation and Characterization)
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