Search Results (12)

Carbon-fiber-reinforced polymer (CFRP) composites are widely used across industries due to their enhanced strength and stiffness properties. Fused deposition modeling (FDM) enables the cost-effective production of polymer samples, such as carbon-fiber-reinforced PLA (CFR-PLA). However, CFRP’s hardness and anisotropic nature present significant challenges in conventional machining, including rapid tool wear and thermal sensitivity. Consequently, abrasive water jet machining (AWJM) has proven to be an effective alternative for machining CFRP materials, offering benefits such as reduced tool wear, minimized thermal damage, and improved cutting quality. This study focuses on a comparative analysis of the effects of AWJM parameters on PLA and CFR-PLA samples, specifically to evaluate the influence of carbon fiber reinforcement on machining performance. The findings highlight the critical role of reinforcements in machining behavior. The results suggest that optimizing cutting parameters significantly reduces taper formation and improves machining accuracy. In particular, adjustments to process parameters resulted in lower taper angles and reduced surface roughness in the cutting zones of the CFR-PLA samples. Full article

Using gas-phase deposition (Physical Vapor Deposition (PVD) and Metal Organic Chemical Vapor Deposition (MOCVD)) methods, modern implant samples (Ti alloy and CFR-PEEK polymer, 30% carbon fiber) were functionalized with film heterostructures consisting of an iridium or gold sublayer, on the surface of which an antibacterial component (silver) was deposited: Ag/Ir(Au)/Ti(CFR-PEEK). The biocidal effect of the heterostructures was investigated, the effect of the surface relief of the carrier and the metal sublayer on antibacterial activity was established, and the dynamics of silver dissolution was evaluated. It has been shown that the activity of Ag/Ir heterostructures was due to high Ag⁺ release rates, which led to rapid (2–4 h) inhibition of P. aeruginosa growth. In the case of Ag/Au type heterostructures, the inhibition of the growth of P. aeruginosa and S. aureus occurred more slowly (from 6 h), and the antibacterial activity appeared to be due to the contribution of two agents (Ag⁺ and Au⁺ ions). It was found, according to the in vitro cytotoxicity study, that heterostructures did not exhibit toxic effects (cell viability > 95–98%). An in vivo biocompatibility assessment based on the results of a morphohistological study showed that after implantation for a period of 30 days, the samples were characterized by the presence of a thin fibrous capsule without volume thickening and signs of inflammation. Full article

Composite booms for solar sails have been prototyped by using innovative smart materials. Shape memory polymer composites (SMPCs) have been manufactured by interposing SMP layers between carbon-fiber-reinforced (CFR) plies. A polyimide membrane has been embedded into the CFR-SMPC frame of the sail during lamination. The sail’s size has been limited to 250 × 250 mm² to allow its testing on Earth. The feasibility of large sail deployments has been shown by prototyping small CFR-SMPC elements to insert only in the folding zones. Numerical simulation by finite element modeling allowed for predicting the presence of wrinkles close to the frame’s vertexes in the cases of large sails under solar radiation pressures. Nevertheless, the frame’s configuration, with SMPC booms at all the edges of the sail membrane, seems to be suitable for drag sails instead of propulsion. On-Earth recovery tests have been performed on 180° folded sails by using flexible heaters. After an initial induction time, the maximum rate was reached with a following drop. In the case of two heaters per folding zone, the angular recovery rate reached the maximum value of about 30 deg/s at the power of 34 W, and full recovery was made in 20 s. Full article

Carbon fiber-reinforced polymers (CFRPs) are being used extensively in modern industries that require a high strength-to-weight ratio, such as aerospace, automotive, motorsport, and sports equipment. However, although reinforcement with carbon fibers improves the mechanical properties of polymers, this comes at the expense of abrasive wear resistance. Therefore, to efficiently utilize CFRPs in dry sliding contacts, solid lubricant is used as a filler. Further, to facilitate the fabrication of objects with complex geometries, selective laser sintering (SLS) can be employed. Accordingly, in the present work, graphite-filled carbon fiber-reinforced polyamide 12 (CFR-PA12) specimens were prepared using the SLS process to explore the dry sliding friction and wear characteristics of the composite. The test specimens were aligned along four different orientations in the build chamber of the SLS machine to determine the orientation-dependent tribological properties. The experiments were conducted using a pin-on-disc tribometer to measure the coefficient of friction (COF), interface temperature, friction-induced noise, and specific wear rate. In addition, scanning electron microscopy (SEM) of tribo-surfaces was conducted to specify the dominant wear pattern. The results indicated that the steady-state COF, contact temperature, and wear pattern of graphite-filled CFR-PA12 are orientation-independent and that the contact temperature is likely to approach an asymptote far below the glass transition temperature of amorphous PA12 zones, thus eliminating the possibility of matrix softening. Additionally, the results showed that the Z-oriented specimen exhibits the lowest level of friction-induced noise along with the highest wear resistance. Moreover, SEM of tribo-surfaces determined that abrasive wear is the dominant wear pattern. Full article

The investigation of destruction processes in composite materials is a current problem for their structural application and the improvement of their functional properties. This work aimed to visualize structural changes induced in layered carbon fiber reinforced plastics (CFRP) with the help of synchrotron X-ray microtomography. This article presents the details of destructive processes in the early stages of the deformation of reinforced polymers under uniaxial stretching, investigated at the micro level. Individual structural elements of the composite–filaments, parallel fiber bundles, the nonuniformity of the polymer binder distribution, and continuity defects—were observed under an external load. We have considered the influence of the material architecture and technological defects on fracture evolution in cross-ply and quasi-isotropic fiber-reinforced plastics. The results indicate the sequence of irreversible structural changes before the destruction of the material. Full article

Shape memory polymer composites (SMPCs) have been manufactured by press moulding of carbon fibre-reinforced (CFR) prepregs with SMP interlayers. SMPC laminates have been produced with different numbers of CFR plies (i.e., 2, 4, 6, and 8) and different thicknesses of the SMP interlayers (i.e., 100 and 300 µm) for a sum of eight combinations. Co-curing of the prepreg plies and the SMP interlayers has led to an optimal adhesion of structural and functional plies, which has been confirmed by following testing. Single thermo-mechanical cycles at increasing strains (i.e., 0.06%, 0.12%, and 0.18%) and multiple cycling have been performed to test SMPC laminate durability. Delamination and fibre cracking were not observed during testing, and laminates showed a reproducible SM behaviour after 10 consecutive thermo-mechanical cycles. SM properties have been extracted from tests in terms of residual and memory loads as well as shape fixity and shape recovery. These data may be used for comparison of the performances of the different laminates, and as a first base for designing SMPC structures. Thin laminates exhibit lower recovery loads but higher shape fixity than thick ones, but the shape recovery is very high for all the SMPCs, with an average of 98%. Full article

In this study, Polyurea/Formaldehyde (PUF) microcapsules containing Dicyclopentadiene (DCPD) as a healing substance were fabricated in situ and mixed at relatively low concentrations (<2 wt%) with a thermosetting polyurethane (PU) foam used in turn as the core of a sandwich structure. The shape memory (SM) effect depended on the combination of the behavior of the PU foam core and the shape memory polymer composite (SMPC) laminate skins. SMPC laminates were manufactured by moulding commercial carbon fiber-reinforced (CFR) prepregs with a SM polymer interlayer. At first, PU foam samples, with and without microcapsules, were mechanically tested. After, PU foam was inserted into the SMPC sandwich structure. Damage tests were carried out by compression and bending to deform and break the PU foam cells, and then assess the structure self-healing (SH) and recovery capabilities. Both SM and SH responses were rapid and thermally activated (120 °C). The CFR-SMPC skins and the PU foam core enable the sandwich to exhibit excellent SM properties with a shape recovery ratio up to 99% (initial configuration recovery). Moreover, the integration of microcapsules (0.5 wt%) enables SH functionality with a structural restoration up to 98%. This simple process makes this sandwich structure ideal for different industrial applications. Full article

The commercial availability of 3D printers for continuous fiber-reinforced 3D-printed (CFR3DP) composites has attracted researchers to evaluate the thermomechanical properties of these materials. The improvement of strength through chopped or continuous fiber reinforcements in polymers could provide remarkable results, and its exploration can provide broad applications in several industries. The evaluation of mechanical properties of these materials at elevated temperatures is vital for their utilization in severe operating conditions. This study provides insight into the effect of different fiber reinforcements (Kevlar, fiberglass, and high-strength high-temperature fiberglass) and temperatures on the creep and recovery behavior of CFR3DP Onyx composites. Experimental results were also compared with analytical models, i.e., Burger’s model and Weibull distribution function, for creep and recovery. Results from analytical models agreed well with experimental results for all the materials and temperatures. A significant drop in maximum and residual strains was observed due to the introduction of fibers. However, the creep resistance of all the materials was affected at higher temperatures. Minimum creep strain was observed for Onyx-FG at 120 °C; however, at the same temperature, the minimum residual strain was observed for Onyx-KF. Based on the analytical models and experimental results, the role of fiber reinforcements on the improvement of creep and recovery performance is also discussed. Full article

The robustness of precast reinforced concrete (RC) frames is relatively poor, while the precast RC frames are strengthened to mitigate progressive collapse, avoiding “strong beams and weak columns” and the anchorage failure of strengthening materials under large deformation condition are the key problems. Aiming to discuss these problems, this paper carried out an experimental research of strengthening on three half-scale assembled monolithic frame subassemblages to mitigate progressive collapse. One specimen was strengthened by implanting carbon fiber rope (CFR) with polymer into concrete, one specimen was strengthened by binding CFR with special knot, and the last one was not strengthened. The failure mode, collapse failure mechanism and strengthening effect of subassemblages were discussed. Analytical models of load capacity increment contributed by CFR and construction suggestions of precast RC frame to mitigate progressive collapse were proposed. The results indicated that none of the strengthened specimens had anchorage failure. The two strengthening methods significantly increased the load capacity of the subassemblages in the catenary action (CA) stage with little effect on the flexural action (FA) stage and compressive arch action (CAA) stage. Full article

In this study, we present improved fusion-bonding strength results between carbon fiber-reinforced polyetheretherketone (CFR-PEEK) and zinc-coated steel through the introduction of pre-inscribed laser surface patterns. Optimized laser welding parameters, including laser power, focal position, pitch, number of passes, and clamping pressure, are presented along with parameters for producing the rectangular laser patterns. It was found that for the optimized parameters, the tensile shear strength of the welded samples is improved by as much as 100% when pre-inscribed laser patterns are present. Detailed SEM images of the fractured fusion welded joint samples after the tensile shear test are presented for analysis. The tight bonding between the polymer matrix and the zinc-coated steel inside the formed grooves is found to be the main reason behind the increased tensile shear strength. A comparison of the tensile shear loads for various joining methods is also presented and discussed. Full article

Fused deposition modeling (FDM) is a rapidly growing three-dimensional (3D) printing technology and has great potential in medicine. Polyether-ether-ketone (PEEK) is a biocompatible high-performance polymer, which is suitable to be used as an orthopedic/dental implant material. However, the mechanical properties and biocompatibility of FDM-printed PEEK and its composites are still not clear. In this study, FDM-printed pure PEEK and carbon fiber reinforced PEEK (CFR-PEEK) composite were successfully fabricated by FDM and characterized by mechanical tests. Moreover, the sample surfaces were modified with polishing and sandblasting methods to analyze the influence of surface roughness and topography on general biocompatibility (cytotoxicity) and cell adhesion. The results indicated that the printed CFR-PEEK samples had significantly higher general mechanical strengths than the printed pure PEEK (even though there was no statistical difference in compressive strength). Both PEEK and CFR-PEEK materials showed good biocompatibility with and without surface modification. Cell densities on the “as-printed” PEEK and the CFR-PEEK sample surfaces were significantly higher than on the corresponding polished and sandblasted samples. Therefore, the FDM-printed CFR-PEEK composite with proper mechanical strengths has potential as a biomaterial for bone grafting and tissue engineering applications. Full article

Glass (GFR) and carbon fiber-reinforced (CFR) dual-cure polymer composites fabricated by UV-assisted three-dimensional (UV-3D) printing are presented. The resin material combines an acrylic-based photocurable resin with a low temperature (140 °C) thermally-curable resin system based on bisphenol A diglycidyl ether as base component, an aliphatic anhydride (hexahydro-4-methylphthalic anhydride) as hardener and (2,4,6,-tris(dimethylaminomethyl)phenol) as catalyst. A thorough rheological characterization of these formulations allowed us to define their 3D printability window. UV-3D printed macrostructures were successfully demonstrated, giving a clear indication of their potential use in real-life structural applications. Differential scanning calorimetry and dynamic mechanical analysis highlighted the good thermal stability and mechanical properties of the printed parts. In addition, uniaxial tensile tests were used to assess the fiber reinforcing effect on the UV-3D printed objects. Finally, an initial study was conducted on the use of a sizing treatment on carbon fibers to improve the fiber/matrix interfacial adhesion, giving preliminary indications on the potential of this approach to improve the mechanical properties of the 3D printed CFR components. Full article