Search Results (299)

Hypersonic vehicles impose stringent requirements on lightweight structures to maintain mechanical integrity under extreme thermal environments. Bismaleimide (BMI)-based carbon fiber-reinforced polymer (CFRP) composites, featuring a high glass transition temperature and excellent thermal stability, are regarded as promising candidates for such applications. However, the high curing temperature and narrow processing window of BMI resins make it challenging to manufacture stiffened-shell structures with low defect levels and high fiber volume fractions. In this study, an integrated manufacturing route—hot-melt prepregging–filament winding–matched-metal mold forming—is proposed, and the key processing parameters are optimized via single-factor experiments and the Box–Behnken response surface methodology. The tensile strength of the laminate is selected as the response variable to evaluate the effects of the compression displacement (A), thermal consolidation/bonding temperature (B), heating rate (C), and cooling rate (D). The results reveal a unimodal dependence of the tensile strength on each parameter, with the significance ranking B > D > A > C; moreover, the A–B and A–D interactions are significant (p < 0.01). The established quadratic regression model exhibits good agreement with experimental data (R² = 0.974; R²_adj = 0.949). The predicted optimum conditions are A = 0.07 mm, B = 114.93 °C, C = 1.35 °C·min⁻¹, and D = 4.58 °C·min⁻¹, corresponding to a predicted tensile strength of approximately 2287 MPa. Validation experiments yielded 2291 MPa, in excellent agreement with the prediction. Microstructural observations indicate tight interlaminar bonding and a pronounced reduction in voids under the optimized conditions. Applying the optimized process to fabricate stiffened-shell demonstrators achieves a fiber volume fraction of >60% and a void content of <1%. This work provides a quantitatively defined processing window and parameter optimization basis for the high-quality manufacturing of BMI-CFRP stiffened-shell structures, with significant engineering relevance. Full article

Epoxy resins with excellent overall performance, are widely used in aerospace, automotive, and related fields, frequently in combination with reinforcing fibers to fabricate composites. To enable controllable epoxy processing for prepreg fabrication and composite forming, a rheological model and a curing kinetics model were developed and experimentally validated for an epoxy resin. Rotational rheometry was conducted to quantify the viscosity evolution with temperature and time, enabling construction of a corresponding rheological model. Comparison between model predictions and experimental measurements exhibited a high level of consistency across a wide temperature range. Furthermore, differential scanning calorimetry (DSC) was employed to measure heat-flow curves at different heating rates. The degree of curing was calculated from the heat-flow data, and an autocatalytic curing kinetics model was established based on a reaction kinetics formulation. And the accuracy of the model was verified by isothermal experiments. The developed rheological model provides a theoretical basis and practical guidance for resin processing and prepreg fabrication, whereas the curing kinetics model supports the design and control of curing and forming schedules for epoxy-matrix composites. Full article

This paper presents a novel carbon fiber reinforced polymer (CFRP) crash box design, incorporating numerical analysis and manufacturing aspects. Within the design and analysis phases, a novel numerical methodology is employed to mitigate computational costs in estimating specific energy absorption (SEA). The proposed approach involves a reduction in ply interfaces and modification of pertinent material properties to optimize energy dissipation, achieving more than 50% reduction in simulation time. This methodology is applied to the design of a composite crash box made of unidirectional (UD) carbon/epoxy prepregs, resulting in a new geometry: sun-like shape featuring four sinusoidal arms connected to a central circular core. Subsequent manufacturing and testing reveal a SEA value of 79.46 J/g for designed geometry, surpassing metallic counterparts by a factor of 3 to 4. Furthermore, this study conducts a comparative analysis of energy absorption performance between unidirectional and woven fabric prepregs for the same geometry. Utilizing carbon/epoxy woven fabric (WF) prepregs further enhances the SEA to 89.26 J/g. Finally, the application of edge tapering to the crash box structure is shown to eliminate initial peak loads, thereby preventing excessive deceleration. Full article

To reduce mold costs in composite forming, multi-point tooling technology has been integrated into the hot diaphragm forming process. However, this approach still faces several challenges, including time-consuming prepreg layup, high energy consumption, and poor surface quality. This study proposes a heating pad-assisted multi-point thermoforming process: the prepreg is embedded in the thermal functional layers, placed on the lower mold, and formed via the downward movement of the upper mold to accomplish mold closure. Instead of the conventional rectangular array, this study adopted multi-point tooling with a hexagonal pin arrangement. Compared to traditional configurations, this hexagonal layout increases the punch support area by 9.8%, while its dense punch arrangement improves the accuracy of the molded curved surface. Taking a saddle-shaped surface as the target, a prototype part was fabricated. Subsequent analysis of the part’s surface quality identified three defects: dimples, fiber distortion, and ridge protrusions. The surface dimples were eliminated by adjusting the distance between the upper and lower molds. Notably, ridge protrusion is a defect unique to the hexagonal pin arrangement. We conducted a detailed analysis of its causes and solutions, finding that this defect arises from the combined effect of the pin arrangement and the saddle-shaped surface. Through a series of height compensation experiments, the maximum deviation at the ridges was reduced from 0.46 mm to approximately 0.35 mm, which is consistent with the deviation of defect-free areas. This work demonstrates that the multi-point hot-pressing process provides a potential, efficient, and low-cost method for manufacturing double-curvature composite components, whose effectiveness has been verified through the saddle-shaped case study. Full article

This study characterised the hot-press forming process of long carbon fibre PA6 materials using laminates prepared from UD-CA708A prepregs manufactured by Nanjing Special Plastic Composites Materials Co., Ltd. In order to investigate the resin flow behaviour during the hot compression moulding process, a unified model integrating the material forming and resin flow sequences was established by Lagrangian and Eulerian discretization methods. Simultaneous measurements by rotational and torsional rheometers revealed that in-plane fibre flow dominated, and the long carbon fibre PA6 material showed anisotropic behaviour. The anisotropic viscosity tensor principal model was used to characterise this anisotropy, the parameters of which were determined experimentally by the rheometer. Based on these findings, a unified modelling approach for material forming and resin flow was developed and applied to simulation analysis. The validity of the anisotropic viscosity intrinsic model and the unified simulation framework is verified by integrating the rheological analysis, in-mold analysis, and evaluation of the microstructure and mechanical properties of the moulded specimens, which provides a technical framework and a strategy for the application of the model in complex geometries. Full article

The mechanical behavior of carbon-fiber-reinforced polymer (CFRP) laminates manufactured using plasma-assisted solvolysis recycled fibers was evaluated experimentally through a comprehensive mechanical testing campaign. The plasma-assisted solvolysis parameters were selected based on an earlier sensitivity analysis. Prepregs made from both virgin and recycled carbon fibers were fabricated via a hand lay-up process and manually stacked to produce unidirectional laminates. Longitudinal tension tests, longitudinal compression tests, and interlaminar shear strength (ILSS) tests were performed to assess the fundamental mechanical response of the recycled laminates and quantify the retention of mechanical properties relative to the virgin-reference material. Prior to mechanical testing, all laminates underwent ultrasonic C-scan inspection to assess manufacturing quality. While both laminate types exhibited generally satisfactory quality, the recycled-fiber laminates showed a higher density of defects. The recycled laminates preserved around 80% of their original tensile strength and maintained an essentially unchanged elastic modulus. Compressive strength was more susceptible to imperfections introduced during remanufacturing, with the recycled laminates exhibiting roughly a 14% decrease compared with the virgin material. On the contrary, the compressive modulus was largely retained. The most substantial reduction occurred in ILSS, which dropped by 58%. Overall, the results demonstrate that plasma-assisted solvolysis enables the recovery of carbon fibers suitable for remanufacturing CFRP laminates, while the observed reduction in mechanical properties of recycled CFRPs is mainly attributed to defects in manufacturing quality rather than to intrinsic degradation of the recycled carbon fibers. Full article

On-orbit cutting is a critical process for the on-orbit manufacturing of carbon fiber reinforced polyetheretherketone composites (CF/PEEK) truss structures, with pulsed laser cutting serving as one of the feasible methods. Achieving high-quality cutting of CF/PEEK remains a major challenge for on-orbit manufacturing. Therefore, the cutting process of CF/PEEK prepreg tape was studied by an ultraviolet (UV) nanosecond laser. A three-factor, five-level orthogonal experiment was carried out to analyze the influence of laser repetition rate (LRR), laser cutting speed (LCS), and laser scanning times (LCTs) on cutting quality. The ablation mechanism dominated by the photothermal effect between the UV nanosecond laser and CF/PEEK was analyzed, and the by-products in the cutting process were explored. Finally, the optimal cutting quality (the width of slit (W_s) = 41.69 ± 3.54 μm, the heat-affected zone (HAZ) = 87.27 ± 7.30 μm) was obtained under the process conditions of LRR 50 kHz-LCS 50 mm/s-LCT 16 times. The findings show that the W_S and HAZ increase with the increase in LRR and LCT and the decrease in LCS, and the carbon fiber decomposes and escapes due to the photothermal effect. Full article

The evolution of tennis equipment is fundamentally linked to advances in materials science and engineering, which have enabled enhanced player performance through optimised racquet and string designs. This review comprehensively examines the critical role of modern composite materials, manufacturing methods, and string technologies in tennis equipment, focusing on how these elements influence mechanical performance and player experience. It first explores the contributions of matrix and reinforcing materials, particularly carbon fibre and aramid composites, to racquet stiffness, strength, and vibration damping. Next, it details advanced manufacturing techniques such as prepreg layup, autoclave curing, and hollow moulding, which enable precise control over mechanical properties and quality assurance. This paper further evaluates various string materials including natural gut, Kevlar, polyester, nylon, and emerging hybrid setups, analysing their mechanical characteristics, tension maintenance, and impact on ball response and player comfort. Special attention is given to the interaction between design choices and playing conditions, such as court surfaces and player sensitivity, underscoring the complex interplay between equipment mechanics and gameplay dynamics. Through an interdisciplinary lens, this paper synthesises current scientific knowledge and experimental findings, providing a critical foundation for optimising tennis equipment design. By integrating materials science with practical application, this paper provides a comprehensive understanding of tennis equipment design, identifying gaps in current research and offering insights to guide future innovation for manufacturers, coaches, and players. Full article

This study first heat-treats the surface of plain-woven carbon fibers to remove the surface sizing. The treated carbon fibers were then hot-pressed with polypropylene films to produce a carbon fiber/polypropylene prepreg. The resulting prepreg was subjected to uniaxial and off-axis tensile tests, providing fundamental data for constructing a constitute model for the carbon fiber/polypropylene prepreg. The relative error between the model predictions and experimental data is maintained within ±10%. Based on the experimental results, a temperature-dependent viscoelastic–hyperelastic constitutive model for carbon fiber/polypropylene is proposed. This model decomposes the unit volume strain energy function into four components: matrix isochoric deformation energy, fiber tensile strain energy, fiber–fiber shear strain energy, and fiber-matrix shear strain energy. The matrix energy is strain rate-dependent, exhibiting viscoelastic mechanical behavior. The material parameters of the constitutive model were identified by fitting the experimental data. The model was implemented in MATLABR2024a, and off-axis tensile tests were performed at temperatures ranging from 423 K to 453 K. Numerical simulations were compared with experimental results to validate the model. This work provides guidance for the development and validation of constitutive models for thermoplastic polypropylene prepregs. Full article

Closed-section composite structures with corners present significant challenges during forming and molding for achieving the desired thickness distribution over the profile. The experimental investigation in the present work was designed to compare laminates constructed entirely from twill-weave carbon fabric prepregs with different hybrid laminates constructed by combining unidirectional (UD) carbon fiber prepregs around the flat and twill-weave fabric prepregs around the curved section. Although the UD fiber prepregs were found to be more compressible than the twill-weave prepregs, the desired thickness distribution (to within 2% of design geometry), along with the proper level of consolidation, was obtained only with the hybrid construction that had an equal number of UD plies around the flat and twill-weave plies around the curved section. In contrast, the thickness distribution obtained with the all-twill prepreg laminate deviated from the design geometry by 5.4%. Forming simulations incorporating experimentally derived compaction behavior of different plies were used to predict the local compaction, tool–ply contact pressures, and thickness profile of the molded part. The simulation results for thickness profiles showed similar trends to those observed in experiments. Full article

Fiber-Metal Laminates (FMLs) are hybrid composite structures of alternating metal layers and fiber-reinforced preimpregnated (prepreg) layers. The purpose of this article is to study numerically the elastic buckling behavior of simply supported FML plates compressed by two equal and opposite forces. More specifically, the main objective of the present study is the calculation of buckling coefficients of thin GLARE plates and the construction of diagrams of these coefficients as a function of their aspect ratio. It is found that the diagrams of the buckling coefficient versus the aspect ratio of aluminum and GLARE plates present a very similar trend. Full article

The presented study is focused on the evaluation of the mechanical and heat resistance performance of the polyester-based injection-molded components. For comparative purposes, we used a poly(ethylene terephthalate)/polycarbonate blend (PET/PC) and a poly(butylene terephthalate)/polycarbonate (PBT/PC) mixture, where both types of polymer blends were used as a matrix for different types of basalt fiber (BF)-reinforced composites. The investigated molding procedure consists of injection overmolding of the composite prepreg (insert). During the technological procedure, various material configurations were used, including overmolding with both unmodified blends and a composition with additional short basalt fibers. The results confirmed that the best balance of properties was obtained for complex parts reinforced with short BF and overmolded insert, where the tensile modulus can reach 8 GPa, while the impact strength was more than 30 kJ/m². The results of comparative tests indicate a significantly higher strength of overmolding joints for PET/PC-based materials. The relatively low heat deflection temp. (HDT) of around 70 °C after the injection molding procedure can be successfully improved by the annealing treatment, where the HDT can reach around 120 °C. The structural tests revealed that, besides some differences in crystallinity between the PET- and PBT-based blends, the thermomechanical performance of the manufactured composites is almost similar. It is worth pointing out the fundamental differences in the miscibility of the investigated blend systems, where for the PBT/PC mixture structural tests confirm the miscibility of polymer phases, while PET/PC particles are immiscible. Full article

This study presents a comparative analysis of two industrially relevant technologies for manufacturing of prepreg composite materials based on polyimide (PI) resin: hot-melt and solvent-based technology. More specifically, the study focuses on evaluating the relationship between key processing parameters and the final properties of the composite material manufactured with unidirectional (UD) C-fibers and woven fabrics used as reinforcement for both technologies. The impregnation process was carried out using a custom-designed coating equipment developed by Mikrosam D.O.O. Manufactured prepregs were characterized in terms of their resin content, volatile content, weight, width, and quality of the applied resin film. The hot-melt method that involves applying the resin in a semi-molten state with minimal solvent content provided a stable resin content (34–35%) and low volatiles (~1.2–1.5%) in the final product. The solvent-based method, using a resin/solvent ratio of 50:50, enabled deeper resin penetration into the fibers, particularly in woven fabrics (resin content: 34–37%) and lower residual volatiles (~0.3–0.5%). These results showed that the hot-melt technology consistently produced prepregs with very stable resin content, which is critical for structural applications requiring increased mechanical performance. In contrast, the solvent-based method demonstrated better adaptability to different reinforcement forms, improved impregnation depth, and excellent film uniformity, particularly suitable for woven fabrics. Representative SEM micrographs confirmed uniform resin distribution, full fiber wetting, and absence of voids, validating the impregnation quality obtained by both techniques. These findings highlight the technological relevance of selecting the appropriate impregnation route for each reinforcement architecture, offering direct guidance for industrial-scale composite manufacturing, where the hot-melt method is preferred for UD prepregs requiring precise resin control, while solvent-based impregnation ensures deeper and uniform resin distribution in woven fabric structures. Full article

This paper proposes a multi-objective optimization method that integrates deep neural networks (DNN) with gray relational analysis (GRA) to optimize lay-up configurations for carbon fiber-reinforced plastic (CFRP) automotive components. Specifically, a lab-scale CFRP B-pillar structure was investigated to simultaneously maximize structural strength and failure safety. A DNN surrogate model was trained using finite element simulations of 2000 random stacking sequences to achieve high predictive accuracy. The trained model was then used to evaluate all possible lay-up combinations to derive Pareto optimal solutions. Gray relational analysis was subsequently employed to select the final optimal configurations based on designer preferences. The selected lay-up designs demonstrated improvements in both strength and failure safety. To validate the proposed framework, laboratory-scale CFRP B-pillar was fabricated using a prepreg compression molding process and subjected to bending tests. The experimental results confirmed an error below 5% and failure trends consistent with the simulation results, thereby validating the reliability of the proposed method. The proposed DNN-GRA approach enables efficient multi-objective optimization with reduced computational effort and flexibility in reflecting different engineering priorities. Full article