Search Results (947)

Difficult, extreme operating conditions of parabolic antennas under precipitation and sub-zero temperatures require the creation of effective heating systems. The purpose of the research is to develop a multilayer coating containing two metal-ceramic layers, epoxy composite layers, carbon fabric, and an outer layer of basalt fabric, which allows for effective heating of the antenna, and to study the properties of this coating. The multilayer coating was formed on an aluminum base that was subjected to abrasive jet processing. The first and second metal-ceramic layers, Al₂O₃ + 5% Al, which were applied by high-speed multi-chamber cumulative detonation spraying (CDS), respectively, provide maximum adhesion strength to the aluminum base and high adhesion strength to the third layer of the epoxy composite containing Al₂O₃. On this not-yet-polymerized layer of epoxy composite containing Al₂O₃, a layer of carbon fabric (impregnated with epoxy resin) was formed, which serves as a resistive heating element. On top of this carbon fabric, a layer of epoxy composite containing Cr₂O₃ and SiO₂ was applied. Next, basalt fabric was applied to this still-not-yet-polymerized layer. Then, the resulting layered coating was compacted and dried. To study this multilayer coating, X-ray analysis, light and raster scanning microscopy, and transmission electron microscopy were used. The thickness of the coating layers and microhardness were measured on transverse microsections. The adhesion strength of the metal-ceramic coating layers to the aluminum base was determined by both bending testing and peeling using the adhesive method. It was established that CDS provides the formation of metal-ceramic layers with a maximum fraction of lamellae and a microhardness of 7900–10,520 MPa. In these metal-ceramic layers, a dispersed subgrain structure, a uniform distribution of nanoparticles, and a gradient-free level of dislocation density are observed. Such a structure prevents the formation of local concentrators of internal stresses, thereby increasing the level of dispersion and substructural strengthening of the metal-ceramic layers’ material. The formation of materials with a nanostructure increases their strength and crack resistance. The effectiveness of using aluminum, chromium, and silicon oxides as nanofillers in epoxy composite layers was demonstrated. The presence of structures near the surface of these nanofillers, which differ from the properties of the epoxy matrix in the coating, was established. Such zones, specifically the outer surface layers (OSL), significantly affect the properties of the epoxy composite. The results of industrial tests showed the high performance of the multilayer coating during antenna heating. Full article

The insulating rod of aramid fiber-reinforced epoxy resin composites (AFRP) is an important component of gas-insulated switchgear (GIS). Under complex working conditions, the high temperature caused by voltage, current, and external climate change becomes one of the important factors that aggravate the interface degradation between aramid fiber (AF) and epoxy resin (EP). In this paper, molecular dynamics (MD) simulation software is used to study the effect of temperature on the interfacial properties of AF/EP. At the same time, the mechanism of improving the interfacial properties of three nanoparticles with different properties (insulator Al₂O₃, semiconductor ZnO, and conductor carbon nanotube (CNT)) is explored. The results show that the increase in temperature will greatly reduce the interfacial van der Waals force, thereby reducing the interfacial binding energy between AF and EP, making the interfacial wettability worse. Furthermore, the addition of the three fillers can improve the interfacial adhesion of the composite material. Among them, Al₂O₃ and CNT maintain a large dipole moment at high temperature, making the van der Waals force more stable and the adhesion performance attenuation less. The Mulliken charge and energy gap of Al₂O₃ and ZnO decrease slightly with temperature but are still higher than AF, which is conducive to maintaining good interfacial insulation performance. Full article

Epoxy resins are widely used as protective coatings in civil infrastructure, yet sulfate-rich environments accelerate their deterioration. This study evaluates the effectiveness of multi-walled carbon nanotubes (MWCNTs) in enhancing the sulfate resistance of epoxy resins. Neat and MWCNT-reinforced epoxy specimens (0.25 wt.% and 0.5 wt.%) were fabricated, heat cured at 100 °C and exposed to a solution of sulfuric acid and sodium chloride maintaining a pH of less than 3 for 0, 30, and 60 days. Analytical techniques, including scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS), revealed distinct degradation patterns: the neat epoxy exhibited puncture damage and extensive salt deposition, while the MWCNT-reinforced specimens showed crack propagation mitigated by nanotube bridging. Heat curing introduced micro-voids that exacerbated sulfate ingress. The salt deposition surged to 200 times for the MWCNT-reinforced specimens compared to the neat ones, whereas crack width was higher in the MWCNT reinforced specimen compared to their neat counterparts, given that crack-bridging was observed. These findings highlight the potential of MWCNTs to improve epoxy durability in sulfate-prone environments, though the optimization of curing conditions and dispersion methods is critical. Full article

This study presents a multi-modal investigation into the wear behavior of bio-based epoxy composites reinforced with multi-walled carbon nanotubes (MWCNTs) at 0–0.75 wt%. A Taguchi L16 orthogonal array was employed to systematically assess the influence of MWCNT content, load (20–50 N), and sliding speed (1–2.5 m/s) on wear rate (WR), coefficient of friction (COF), and surface roughness (Ra). Statistical analysis revealed that MWCNT content contributed up to 85.35% to wear reduction, with 0.5 wt% identified as the optimal reinforcement level, achieving the lowest WR (3.1 mm³/N·m) and Ra (0.7 µm). Complementary morphological characterization via SEM and AFM confirmed microstructural improvements at optimal loading and identified degradation features (ploughing, agglomeration) at 0 wt% and 0.75 wt%. Regression models (R² > 0.95) effectively captured the nonlinear wear response, while a Random Forest model trained on GLCM-derived image features (e.g., correlation, entropy) yielded WR prediction accuracy of R² ≈ 0.93. Key image-based predictors were found to correlate strongly with measured tribological metrics, validating the integration of surface texture analysis into predictive modeling. This integrated framework combining experimental design, mathematical modeling, and image-based machine learning offers a robust pathway for designing high-performance, sustainable nanocomposites with data-driven diagnostics for wear prediction. Full article

Automated fiber placement (AFP) composites exhibit complex mechanical behaviors due to manufacturing-induced mesostructural variations, including resin-rich regions and tow gaps that significantly influence both local stress distributions and global material responses. This study presents a hierarchically nested modeling framework based on the Parametric High-Fidelity Generalized Method of Cells (PHFGMC) to predict the effective elastic properties and nonlinear mechanical response of AFP composites. The PHFGMC model integrates micro- and meso-scale analyses using representative volume elements (RVEs) derived from micrographs of AFP composite laminates to capture these manufacturing-induced characteristics. Multiple RVE configurations with varied gap patterns are analyzed to quantify the influence of mesostructural features on global stress–strain response. Predictions for linear and nonlinear elastic behaviors are validated against experimental results from carbon fiber/epoxy AFP specimens, demonstrating good quantitative agreement with measured responses. A cohesive extension of the PHFGMC framework further captures damage initiation and crack propagation under transverse tensile loading, revealing failure mechanisms specifically associated with tow gaps and resin-rich areas. By systematically accounting for manufacturing-induced variability through detailed RVE modeling, the nested PHFGMC framework enables the accurate prediction of global mechanical performance and localized behavior, providing a robust computational tool for optimizing AFP composite design in aerospace and other high-performance applications. Full article

Achieving carbon neutrality requires not only reducing CO₂ emissions but also capturing atmospheric CO₂. Direct air capture (DAC) using amine-based adsorbents has emerged as a promising approach. In this study, we developed amine-epoxy/poly(vinyl alcohol) (AE/PVA) nanofibers via electrospinning and in situ thermal polymerization. PVA was incorporated to enhance spinnability, and B-staging of AE enabled fiber formation without inline heating. We systematically investigated the effects of electrospinning parameters, epoxy-to-amine ratios (E/A), and the degree of PVA saponification on CO₂ adsorption performance. Thinner fibers, obtained by adjusting spinning conditions, exhibited faster adsorption kinetics due to increased surface area. Varying the E/A revealed a trade-off between adsorption capacity and low-temperature desorption efficiency, with secondary amines offering a balanced performance. Additionally, highly saponified PVA improved thermal durability by minimizing side reactions with amines. These findings highlight the importance of optimizing fiber morphology, chemical composition, and polymer properties to enhance the performance and stability of AE/PVA nanofibers for DAC applications. Full article

Carbon nanotubes (CNTs) and graphene nanoplatelets (GNPs) have attracted significant interest as hybrid reinforcements in epoxy (Ep) composites for enhancing mechanical performance in structural applications, such as aerospace and automotive. These 1D and 2D nanofillers possess exceptionally high aspect ratios and intrinsic mechanical properties, substantially improving composite stiffness and tensile strength. In this study, epoxy nanocomposites were fabricated with 0.1 wt.% and 0.3 wt.% of CNTs and GNPs individually, and with 1:1 CNT:GNP hybrid fillers at equivalent total loadings. Scanning electron microscopy of fracture surfaces confirmed that the CNTGNP hybrids dispersed uniformly, forming an interconnected nanostructured network. Notably, the 0.3 wt.% CNTGNP hybrid system exhibited minimal agglomeration and voids, preventing crack initiation and propagation. Mechanical testing revealed that the 0.3 wt.% CNTGNP/Ep composite achieved the highest tensile strength of approximately 84.5 MPa while maintaining a well-balanced stiffness profile (elastic modulus ≈ 4.62 GPa). The hybrid composite outperformed both due to its synergistic reinforcement mechanisms and superior dispersion despite containing only half the concentration of each nanofiller relative to the individual 0.3 wt.% CNT or GNP systems. In addition to mechanical performance, electrical conductivity analysis revealed that the 0.3 wt.% CNTGNP hybrid composite exhibited the highest conductivity of 0.025 S/m, surpassing the 0.3 wt.% CNT-only system (0.022 S/m), owing to forming a well-connected three-dimensional conductive network. The 0.1 wt.% CNT-only composite also showed enhanced conductivity (0.0004 S/m) due to better dispersion at lower filler loadings. These results highlight the dominant role of CNTs in charge transport and the effectiveness of hybrid networks in minimizing agglomeration. These findings demonstrate that CNTGNP hybrid fillers can deliver optimally balanced mechanical enhancement in epoxy matrices, offering a promising route for designing lightweight, high-performance structural composites. Further optimization of nanofiller dispersion and interfacial chemistry may yield even greater improvements. Full article

In recent times, fiber reinforced polymer composite materials have become more popular due to their remarkable features such as high specific strength, high stiffness and durability. Particularly, Carbon Fiber Reinforced Polymer (CFRP) composites are one of the most prominent materials used in the field of transportation and building engineering, replacing conventional materials due to their attractive properties as mentioned. In this work, a CFRP laminate is fabricated with carbon fiber mats and epoxy by a hand layup technique. Alumina (Al₂O₃) micro particles are used as a filler material, mixed with epoxy at different weight fractions of 0% to 4% during the fabrication of CFRP laminates. The important objective of the study is to investigate the influence of alumina micro particles on the mechanical performance of the laminates through characterization for various physical and mechanical properties. It is revealed from the results of study that the mass density of the laminates steadily increased with the quantity of alumina micro particles added and subsequently, the porosity of the laminates is reduced significantly. The SEM micrograph confirmed the constituents of the laminate and uniform distribution of Al₂O₃ micro particles with no significant agglomeration. The hardness of the CFRP laminates increased significantly for about 60% with an increase in weight % of Al₂O₃ from 0% to 4%, whereas the water gain % gradually drops from 0 to 2%, after which a substantial rise is observed for 3 to 4%. The improved interlocking due to the addition of filler material reduced the voids in the interfaces and thereby resist the absorption of water and in turn reduced the plasticity of the resin too. Tensile, flexural and inter-laminar shear strengths of the CFRP laminate were improved appreciably with the addition of alumina particles through extended grain boundary and enhanced interfacial bonding between the fibers, epoxy and alumina particles, except at 1 and 3 wt.% of Al₂O₃, which may be due to the pooling of alumina particles within the matrix. Inclusion of hard alumina particles resulted in a significant drop in impact strength due to appreciable reduction in softness of the core region of the laminates. Full article

In carbon-fiber-reinforced composites, hydroxyl and carboxyl groups are formed on the carbon fiber surface as a result of the oxidation process applied to the fibers. These groups strengthen the interfacial bond between the fibers and the epoxy resin. In addition, the silanization process chemically bonds amino and glycidyl groups to the fiber surface, further improving adhesion and thus optimizing the performance of the joint. In light of this, the primary objective of the present study is to optimize the performance of adhesive joints by applying oxidation and silane modifications to the fibers added to the adhesive and the bonded metal materials. In this study, carbon fibers underwent oxidation treatment for 5, 10, and 20 min, followed by silanization with 3-aminopropyltriethoxysilane (APTES) and glycidoxypropyltrimethoxysilane (GPTMS) silane agents. Additionally, the surfaces of the bonded aluminum materials were subjected to a 10 min oxidation process, followed by silanization with APTES and GPTMS silane agents. The tensile test performance of single-lap joints, bonded using chemically surface-treated aluminum and composite adhesives containing 2 wt.% chemically treated carbon fibers, was experimentally investigated. According to the contact angle measurement results obtained in this study, aluminum materials subjected to oxidation treatment exhibited superhydrophilic behavior, whereas materials subjected to silanization displayed hydrophilic behavior. A similar trend was observed in the fibers. The performance of adhesive joints increased by approximately 14% when only the aluminum materials underwent oxidation treatment. Moreover, the addition of 2 wt.% carbon fibers to the adhesive enhanced the joint performance by approximately 31%. However, when oxidation treatments of varying durations were applied to both the aluminum materials and the fibers, the joint performance improved by approximately 35% to 40%. When silanization treatments were applied in addition to the oxidation treatments on aluminum and fiber surfaces, the joint performance increased by approximately 68% to 70%. These findings were corroborated through analyses performed using 3D profilometry and Scanning Electron Microscopy (SEM) imaging. Full article

In this work, the mechanical properties of composites with a polymer matrix and reinforced with carbon particles have been studied. It has been established that the obtained engineering materials have increased elastic and plastic characteristics. The thermosetting polymers used are epoxy, polyester, and vinylester resins. The carbon particles are carbon nanotubes and waste carbon from the plasma decomposition of methane in the production of green hydrogen. The carbon particles used are in an amount of 1 wt% and 2 wt% of the weight of the composite, and they are not subjected to pre-treatment (modification). The studied composites are used in shipping, automotive, and aviation technology, and the presence of carbon particles in them is a prerequisite for improving their anti-radar properties. Full article

Prefabricated unidirectional carbon fiber reinforced polymer (CFRP) composite strips are extensively used as a means of infrastructure rehabilitation through adhesive bonding to the external surface of structural concrete elements. Most data to date are from laboratory tests ranging from a few months to 1–2 years providing an insufficient dataset for prediction of long-term durability. This investigation focuses on the assessment of the response of three different prefabricated CFRP systems exposed to water, seawater, and alkaline solutions for 5 years of immersion in deionized water conducted at three temperatures of 23, 37.8 and 60 °C, all well below the glass transition temperature levels. Overall response is characterized through tensile and short beam shear (SBS) testing at periodic intervals. It is noted that while the three systems are similar, with the dominant mechanisms of deterioration being related to matrix plasticization followed by fiber–matrix debonding with levels of matrix and interface deterioration being accelerated at elevated temperatures, their baseline characteristics and distributions are different emphasizing the need for greater standardization. While tensile modulus does not degrade appreciably over the 5-year period of exposure with final levels of deterioration being between 7.3 and 11.9%, both tensile strength and SBS strength degrade substantially with increasing levels based on temperature and time of immersion. Levels of tensile strength retention can be as low as 61.8–66.6% when immersed in deionized water at 60 °C, those for SBS strength can be 38.4–48.7% at the same immersion condition for the three FRP systems. Differences due to solution type are wider in the short-term and start approaching asymptotic levels within FRP systems at longer periods of exposure. The very high levels of deterioration in SBS strength indicate the breakdown of the materials at the fiber–matrix bond and interfacial levels. It is shown that the level of deterioration exceeds that presumed through design thresholds set by specific codes/standards and that new safety factors are warranted in addition to expanding the set of characteristics studied to include SBS or similar interface-level tests. Alkali solutions are also shown to have the highest deteriorative effects with deionized water having the least. Simple equations are developed to enable extrapolation of test data to predict long term durability and to develop design thresholds based on expectations of service life with an environmental factor of between 0.56 and 0.69 for a 50-year expected service life. Full article

Type IV composite overwrapped pressure vessels (COPVs) store hydrogen at pressures up to 70 MPa and must meet stringent safety standards through physical testing. However, full-scale burst, plug torque, axial compression, impact, and drop tests are time-consuming and costly. This study proposes a unified finite element analysis (FEA) workflow that replicates these mandatory tests and predicts failure behavior without physical prototypes. Axisymmetric and three-dimensional solid models with reduced-integration elements were constructed for the polyamide liner, aluminum boss, and carbon/epoxy composite. Burst simulations showed that increasing the hoop-to-axial stiffness ratio shifts peak stress to the cylindrical region, promoting a longitudinal rupture—considered structurally safer. Plug torque and axial load simulations revealed critical stresses at the boss–composite interface, which can be reduced through neck boss shaping and layup optimization. A localized impact with a 25 mm sphere generated significantly higher stress than a larger 180 mm impactor under equal energy. Drop tests confirmed that 45° oblique drops cause the most severe dome stresses due to thin walls and the lack of hoop support. The proposed workflow enables early-stage structural validation, supports cost-effective design optimization, and accelerates the development of safe hydrogen storage systems for automotive and aerospace applications. Full article

Hybrid fiber-reinforced polymer-laminated composites are often used under icy conditions (such as for reinforcing parts in aircraft frames and bridge beams), where there is an urgent demand for deicing. In this paper, besides the different mechanical properties of laminates along the longitudinal carbon fiber (CF) and glass fiber (GF) directions, the anisotropic electrothermal behavior of a hybrid glass/carbon fiber-reinforced epoxy (GCF/EP) is also investigated, as well as its deicing performance and self-repairing capability. The surface equilibrium temperature of GCF/EP composites can conveniently be adjusted by tuning the current magnitude and its flow direction. Compared to the longitudinal CF direction of the GCF/EP, where 0.3 A was loaded to achieve a surface equilibrium temperature of 122.8 °C, a much weaker current (0.03 A) was needed to load along the longitudinal GF direction to reach almost the same temperature. However, besides the higher flexural strength and fast temperature response, along the longitudinal CF direction, the GCF/EP exhibited excellent deicing performance, including a shorter time and larger energy efficiency. Furthermore, the self-repairing ability of the GCF/EP and its effect on the deicing performance of the composite were characterized. Studying the Joule heating effect of GCF/EP composite laminates and their corresponding deicing performance lays the foundation for their design and practical application in icy environments. Full article

The epoxy-bonded joint between carbon-fiber-reinforced bismaleimide (CF-BMI) and quartz-fiber-reinforced bismaleimide (QF-BMI) composites can meet the structure–function integration requirements of next-generation aviation equipment, and the structural design of their bonding zones directly affects their service performance. Hence, in this study, the carbon-fiber-reinforced bismaleimide composite ZT7H/5429, the woven quartz-fiber-reinforced bismaleimide composite QW280/5429, and epoxy adhesive film J-116 were used as research materials to investigate the influence of the bonding area size on the mechanical properties, and this study proposes a novel design methodology combining radial basis function (RBF) neuron machine learning with the NSGA-II algorithm to enhance the mechanical properties of the bonded components. First, a finite element simulation model considering 3D hashin criteria and cohesion was established, and its accuracy was verified with experiments. Second, the RBF neuron model was trained using the finite element tensile strength and shear strength data from various adhesive layer parameter combinations. Then, the multi-objective parameter optimization of the surrogate model was accomplished through the NSGA-II algorithm. The research results demonstrate a high consistency between the finite element simulation results and experimental outcomes for the epoxy-bonded CF/QF-BMI composite joint. The stress distribution of the adhesive layers is similar under the different structural parameters of adhesive films, though the varying structural dimensions of the adhesive layers lead to distinct failure modes. The trained RBF neuron model controls the prediction error within 2.21%, accurately reflecting the service performance under various adhesive layer parameters. The optimized epoxy-bonded CF/QF-BMI composite joint exhibits 16.1% and 11.2% increases in the tensile strength and shear strength, respectively. Full article

Liquid hydrogen (LH₂) storage using carbon-fiber-reinforced composite pressure vessels is facing increasing demands in aerospace engineering. However, hydrogen permeation in epoxy resin matrixes seriously jeopardizes the function and safety of the cryogenic vessels, and the micro-behavior of hydrogen permeation in epoxy resins remains mysterious. This study performed molecular dynamics (MD) simulations to investigate the hydrogen molecule permeation behaviors in two types of epoxy resin systems, with similar epoxy reins of bisphenol A diglycidyl ether (DGEBA) and different curing agents, i.e., 4,4′-diaminodiphenylmethane (DDM) and polypropylene glycol bis(2-aminopropyl ether) (PEA). The influencing factors, including the cross-linking degrees and temperatures, on hydrogen permeation were analyzed. It was revealed that increased cross-linking degrees enhance the tortuosity of hydrogen diffusion pathways, thereby inhibiting permeation. The adsorption characteristics demonstrated high sensitivity to temperature variations, leading to intensified hydrogen permeation at low temperatures. By triggering defects in the epoxy resin systems by uniaxial tensile simulation, high consistency between the simulation results and the results from helium permeability experiments can be achieved due to the micro-defects in the simulation model that are more realistic in practical materials. The findings provide theoretical insights into micro-scale permeation behavior and facilitate the development of high-performance epoxy resins in liquid hydrogen storage. Full article