Search Results (511)

The rapid expansion of space exploration has increased the demand for lightweight structural materials capable of maintaining performance under extreme thermal conditions. Carbon fibre-reinforced polymers (CFRPs) offer high specific strength and low density; however, their application in cryogenic environments remains challenging due to the brittleness of epoxy matrices, which are susceptible to cracking at low temperatures and under thermal cycling. In this work, two strategies were investigated to improve the damage tolerance of epoxy nanocomposites: (i) the use of a biscitraconimide-based (BCI) resin and (ii) the incorporation of methyl methacrylate–butadiene–styrene (MBS) core–shell particles. Low additive contents were evaluated to identify formulations compatible with prepreg manufacturing. The incorporation of 2 wt.% of MBS core–shell particles significantly improved the impact resistance of the nanocomposites and was selected for CFRP laminate production. When applied to CFRPs, the modified matrix maintained the overall tensile behaviour while increasing the interlaminar fracture toughness by 102% and 122% at room (RT) and cryogenic temperatures (CT), respectively. These findings demonstrate that matrix modification using low-content toughening is an effective strategy to enhance the cryogenic performance of CFRPs, contributing to the development of lighter and more resilient composite structures for next-generation space systems. Full article

Aramid nanofibers (ANFs) inherit the exceptional properties of the bulk counterparts, while introducing a large specific surface area and excellent processability. However, the strong inter-fibrillar interactions and tendency to agglomerate hinder their high-content incorporation into polymer matrices. Here, we report a one-pot reprotonation–compounding strategy for fabricating aramid nanofiber-reinforced poly(vinyl alcohol) (ANF–PVA) composite films, where the ANF dispersion was mixed with polymers during the protonation process to form a continuous 3D network in the ANF-PVA film. The optimized film with a loading of 20 wt% ANFs exhibited a tensile strength of 122.2 MPa and a toughness of 28.36 J m⁻³. Furthermore, the high ANF loading enabled versatile applications. A robust ANF-PVA hydrogel, prepared via salt-induced gelation, delivered 132% enhancement in tear strength and 38.2% increase in cyclic compressive strength compared with the PVA hydrogel. Moreover, inspired by the “brick-and-mortar” architecture of natural nacre, the fully organic ANF-PVA film was incorporated into carbon fiber/epoxy laminates, with a configuration of one nacre-inspired film per five prepreg plies, achieving a 36.5% improvement in impact toughness and minimal loss in flexural strength. This scalable reprotonation–compounding approach provides a general route for producing high-loading ANF-based composites, paving the way for the broader utilization in advanced materials. Full article

Thermally sprayed metallic coatings on carbon fiber-reinforced polymer (CFRP) substrates often contain pores and microstructural defects that can reduce adhesion, durability, and protective performance. In this study, a hybrid graphene nanoplatelet (GNP)-fullerene C60 reinforced epoxy coating was applied to HVOF-metallized CFRP, while a carbon nanotube (CNT)-based surface treatment was used to modify surface wettability. Micro-CT and SEM analyses indicated morphological changes consistent with partial coverage of accessible surface-connected defects and modification of the metallized layer surface. Pull-off adhesion strength increased from 320 psi to 650 psi, accompanied by a shift from adhesive to cohesive failure. The optimal nanofiller formulation improved tensile strength from approximately 25 MPa to 56 MPa (124%) and Young’s modulus by approximately 47% compared with neat epoxy. Abrasion testing showed more than 50% reduction in mass loss, and electrochemical impedance spectroscopy indicated improved barrier performance after 200 h of salt spray exposure. CNT surface modification transformed the coating from hydrophilic to superhydrophobic behavior, achieving water contact angles above 155°, delaying ice formation, and reducing ice accumulation. These results indicate that combining hybrid nanocomposite coatings with CNT functionalization can improve mechanical, protective, and surface-functional performance of HVOF-metallized CFRP systems under the laboratory conditions investigated. Full article

The growing replacement of metallic alloys by polymer matrix composites in the transport and mobility industries has intensified the need for reliable methods to predict the strength of laminates weakened by fastener holes. As a preliminary step toward the design of composite bolted joints, this work investigates the open-hole (notched) tensile strength of carbon fiber/epoxy laminates using a uniaxial fracture framework based on both the Point Stress Criterion (PSC) and the Average Stress Criterion (ASC) of Whitney and Nuismer. Six balanced carbon/epoxy fabric stacking sequences ranging from [0]₅ to [45]₅ were analyzed for four different hole diameters (3.18, 6.35, 9.52, and 12.70 mm), together with the unnotched reference, totaling 30 evaluated conditions (six different stacking sequences × four different hole diameters and one unnotched laminate). The Konish–Whitney analytical stress distribution was applied to both criteria. The characteristic dimensions d₀ (PSC) and a₀ (ASC) were obtained by fitting reference experimental data. The ASC integral was evaluated numerically over the same stress distribution used for the PSC. A complementary two-dimensional finite-element model with 360-element azimuthal mesh refinement was developed and validated against the classical isotropic infinite-plate solution (K_t ≈ 3), with an accuracy better than 0.1%. Across all 24 (laminate × diameter) combinations, the ASC reduced the root-mean-square prediction error from 15.1% (PSC) to 11.0%, and the mean absolute error from 11.7% to 7.8%. For balanced [0/45] configurations both criteria remained within ±10% of the experimental notched strength, with the ASC narrowing the band to ±3.6%; unidirectional laminates, non-conservative by up to 16% under the PSC, were brought below 7% by the ASC, and ±45°, dominated stacks remained conservative (15–23%), reflecting matrix-driven failure mechanisms outside the scope of either point-wise criterion. Condensed error maps are used to delineate the envelope of applicability of each criterion on the fabric laminate dataset of Soriano and Almeida. The comparative assessment supports the ASC as the more accurate of the two criteria for fiber-controlled configurations within the dataset, while highlighting that any transfer of the calibrated characteristic dimensions to other material systems, geometries, or off-axis-dominated layups would require dedicated validation and, for off-axis stacks, progressive damage modeling. Full article

In this work, composites based on thermosetting polymers (epoxy, polyester and vinylester resins) are presented, in which carbon particles and cenospheres are embedded. The influence of combinations of multi-walled carbon nanotubes (MWCNTs) and cenospheres, as well as amorphous carbon and cenospheres, on the mechanical properties and electromagnetic attenuation in (part of) the X-band range (812 GHz) of the developed composites has been studied. It has been established that the used combinations of carbon particles and cenospheres have the greatest positive effect on the mechanical properties of the composites based on vinylester resin. The developed materials demonstrate effectiveness for electromagnetic protection in the X-band range. The combination of a polymer matrix and appropriate fillers leads to significant attenuation of the radio frequency signal. The presented composites are suitable materials for integration into various defense systems—from coatings to structural elements with functional purposes. Full article

Multi-material structures such as carbon fiber reinforced polymer (CFRP) and epoxy resin are increasingly used in modern power equipment. However, significant differences in their thermophysical properties result in distinct defect thermal responses, which can reduce the reliability of infrared thermography inspections. To address this issue, this study investigates the thermal response mechanisms and quantitative analysis of defects in multi-material power equipment through finite element simulation and experimental validation. Three-dimensional transient heat transfer models containing air voids and heterogeneous insert defects were established using COMSOL Multiphysics for both carbon fiber reinforced polymer and epoxy resin matrices. Pulsed infrared thermography experiments were subsequently conducted to verify the simulation results. The effects of material properties, defect geometry, and cover-layer thickness on thermal response characteristics were systematically analyzed. The results show that thermal diffusivity is the key factor governing defect signal evolution. Carbon fiber reinforced polymer exhibits rapid thermal propagation and early transient responses, whereas epoxy resin produces delayed and slowly increasing thermal signals. Greater defect depth weakens thermal contrast and delays peak response time, while larger defect diameters enhance defect detectability. Increasing cover-layer thickness significantly attenuates defect signals and reduces imaging contrast. Experimental results are in good agreement with simulation predictions, confirming the validity of the proposed models. This work provides a quantitative analysis of defect thermal behavior in multi-material systems and offers a theoretical basis for adaptive infrared thermography inspection and condition assessment of power equipment. It should be noted that this study focuses on mechanistic understanding and parametric analysis rather than on proposing a dedicated quantitative defect-sizing or inversion method. Full article

Carbon fiber-reinforced polymer (CFRP) repair is widely used to rehabilitate corroded steel pipelines; however, the relative influence of CFRP repair geometry on stress reduction remains insufficiently quantified. This study investigated the effects of CFRP thickness and repair length on the hoop stress response of steel pipelines containing circumferentially uniform longitudinal corrosion defects under internal pressure. An axisymmetric finite element model was developed in ABAQUS and verified against an analytical multilayer cylinder solution based on the Lamé thick-cylinder theory. The model was based on an idealized circumferentially uniform corrosion defect, linear elastic material behavior, and perfect bonding between the steel pipe, epoxy filler, and CFRP repair layer. A parametric study was performed by varying the defect depth, defect length, CFRP thickness, and repair length. The results showed that CFRP thickness was the dominant parameter controlling the repair effectiveness. For the deepest defect case, increasing the CFRP thickness ratio from 0.25 to 0.75 increased the hoop stress reduction from approximately 40% to more than 58% for the shorter defect and from approximately 40% to more than 62% for the longer defect case. In contrast, increasing the repair length beyond full defect coverage produced only marginal additional stress reduction. Based on a 10% stress-tolerance criterion relative to the intact pipe response, the required CFRP thickness-to-defect-depth ratio increased with defect severity. These findings support the preliminary CFRP repair sizing by prioritizing repair thickness over excessive repair length. Full article

Ambient-curing epoxy–urethane reactive polymer composites require a balance between initial flowability and subsequent structure buildup. In this study, epoxy–urethane reactive polymer composites containing precipitated calcium carbonate were prepared and referred to as EUPC formulations. Their rheological evolution was characterized by flow sweep, temperature sweep, time sweep, three-interval thixotropy tests (3ITT), amplitude sweep, and oscillatory time sweep. The formulations exhibited distinct initial flow resistance and strong temperature sensitivity, with apparent viscosity decreasing as temperature increased. During ambient curing, viscosity increased continuously, indicating progressive rheological buildup under the selected testing conditions. The 3ITT results showed high-shear-induced apparent viscosity reduction followed by recovery-stage viscosity evolution after returning to the low-shear condition, indicating that the recovery index should be interpreted as an apparent post-shear recovery index rather than a purely thixotropic recovery parameter. Oscillatory measurements revealed a gradual transition from viscous-dominated to more elastic-dominated behavior, and the apparent gel time followed the sequence EUPC-2 < EUPC-4 < EUPC-1 < EUPC-3 < EUPC-5 < EUPC-6. These results indicate that EUPC processability and structure buildup should be evaluated by integrating initial viscosity, temperature sensitivity, post-shear response, and operational viscous-to-elastic transition. Full article

Lightweight polymer composites with effective electromagnetic interference (EMI) shielding are of increasing interest for advanced electronic and aerospace applications; however, conventional glass fiber-reinforced polymers (GFRPs) exhibit inherently low electrical conductivity, limiting their shielding performance. In this study, a hierarchical hybrid conductive architecture was developed by integrating graphene-coated multiaxial glass fiber fabrics with carbon black (CB)-reinforced epoxy matrices to enhance EMI shielding behavior in the X-band (8–12 GHz). Graphene coatings were deposited onto glass fibers via a surfactant-assisted ultrasonic dispersion method, while carbon black (0–1 wt.%) was incorporated into the epoxy matrix using ultrasonication-assisted mixing. Multilayer composites were fabricated using a vacuum bagging process. X-ray diffraction analysis revealed that the composites retained a predominantly amorphous epoxy/glass fiber matrix while exhibiting broad carbon-related diffraction features associated with disordered graphitic domains. Electrical conductivity measurements indicated that all composites remained in the insulating regime (~10⁻⁹ S/m), suggesting that a fully interconnected conductive network was not established within the investigated filler range. Despite the absence of a continuous conductive network, measurable EMI shielding performance was achieved. The composite containing 0.25 wt.% CB exhibited the highest shielding effectiveness, reaching approximately 12 dB at ~11.2 GHz. Analysis of the shielding contributions showed that absorption contributions (SEA) were consistently higher than reflection contributions (SER) across the studied frequency range. Morphological observations revealed that well-dispersed CB at low loading facilitated the formation of localized conductive domains that may contribute to tunneling-assisted polarization and interfacial charge accumulation. At higher CB contents, particle agglomeration reduced dispersion quality and limited effective pathway formation, while dynamic mechanical analysis indicated enhanced stiffness at low CB loading. FTIR results confirmed the absence of new chemical bonding, indicating that CB acts as a physically dispersed conductive filler. Overall, the results show that effective EMI shielding can be achieved in electrically insulating composites through the combined effect of hierarchical structural design and localized conductive features. This approach provides a practical pathway for developing lightweight EMI shielding materials with controlled filler loading and preserved structural integrity for aerospace and electronic applications. Full article

Femtosecond laser surface texturing offers a promising route to tailor the functionality of bio-based wood coatings, yet the interplay between coating composition and laser processing remains poorly understood. In this study, bio-based epoxy coatings with eventual micronized wax additives were textured using a femtosecond laser to investigate the effects of laser processing parameters on pattern formation and resulting hydrophobicity. The epoxy coatings containing PE, PE/PTFE, HDPE, and rice bran waxes at 1, 5, and 7 wt.-% were characterized in terms of morphology, roughness, wettability, and chemical stability, followed by systematic variation of pulse repetition rate and laser power. The results reveal that the ablation threshold strongly depends on intrinsic coating properties. Ablation resistance increases with surface roughness and wax melting enthalpy, reflecting the role of phase transition energy in laser–matter interaction. The wax-filled coatings exhibit a transition from melting-dominated behavior at low energy input to ablation-dominated behavior at a higher energy. Laser texturing enhances hydrophobicity in parallel with theoretical values calculated from the Cassie–Baxter wetting model, with the highest hydrophobicity achieved for coatings combining intrinsic hydrophobicity and stable pattern formation. Chemical analysis confirms limited degradation of the epoxy matrix without significant carbonization, while wax additives provide partial thermal shielding. Overall, this work demonstrates clear options for tailoring surface morphology and wettability of hydrophobic polymer coatings through controlled femtosecond laser processing. Full article

Carbon nanotube (CNT)-reinforced composites are promising advanced materials due to their exceptional mechanical properties. This paper presents a comprehensive investigation of the mechanical behavior of CNT/epoxy composites through theoretical modeling and experimental validation. An equivalent cylindrical fiber model was developed to transform CNTs into effective reinforcement phases, enabling the application of classical composite mechanics. Three reinforcement configurations were analyzed: two unidirectional short fiber models (aligned and staggered) and a three-dimensional four-directional braided long-fiber model. The effects of geometric parameters, including the diameter-to-thickness ratio (D/t) and fiber aspect ratio, on the effective elastic moduli were systematically evaluated. Static and dynamic compression experiments were conducted using an MTS 810 testing system and a Split Hopkinson Pressure Bar (SHPB) to examine the influence of loading rate, vacuum treatment, and reinforcement type (CNT, SiC, and hybrid SiC/CNT) on composite strength. The results indicated that 3 wt% CNT reinforcement increases the Young’s modulus by 30% under static loading and enhanced the dynamic compressive strength under impact loading. The vacuum degassing process significantly affected composite quality, with insufficient vacuum leading to strength degradation due to void formation. Theoretical predictions using Mori–Tanaka and dilute methods showed good agreement with experimental results at low reinforcement volume fractions. Scanning electron microscopy revealed uniform CNT dispersion and provided insights into failure mechanisms, including CNT pull-out and breakage. This work contributes to the understanding of structure–property relationships in CNT-reinforced polymer composites and provides guidelines for achieving their optimal design. Full article

The rapid growth in the use of carbon fiber-reinforced polymers (CFRPs) and fused-deposition-modeled (FDM) polylactic acid (PLA) has generated substantial non-biodegradable and thermoplastic waste streams, creating urgent needs for scalable recycling and valorization strategies. This study develops and evaluates an integrated route that chemically recovers carbon fibers (CFs) from CFRP waste and converts them into high-performance reinforcements for recycled PLA matrices. CFRP fragments were pre-swollen in acetic acid (120 °C, 1 h), then depolymerized by means of oxidation with 1 M KMnO₄ (100 °C, 2 h), washed, dried (100 °C, 24 h), and size-reduced by means of cryogenic milling. Recycled CFs (treated) and untreated CFRP fragments were blended with 3D-printing PLA waste at 10, 20 and 30 wt.% via melt mixing (175 °C, 5 min, 70 rpm) and molded into ASTM D638 dog-bone specimens. Materials were characterized via XRD, FTIR, Raman, SEM and mechanical testing. XRD and Raman confirmed retention of the graphitic backbone after treatment; FTIR and Raman revealed oxygen-containing surface functionalization consistent with oxidation, while SEM showed effective removal of epoxy and improved fiber surface cleanliness. Compared with neat PLA (tensile strength 45.4 MPa; modulus 2.6 GPa; elongation 6.3%), composites reinforced with chemically recycled CFs exhibited marked mechanical enhancement: at 30 wt.% treated CF, the tensile strength increased to 102.6 MPa (+126%), elastic modulus to 11.7 GPa (+350%), and toughness to 250.3 MPa, while ductility decreased to 2.9%. Equivalent composites with untreated CFRP exhibited smaller gains (30 wt.%: tensile 87.3 MPa; modulus 10.3 GPa), highlighting the benefit of epoxy removal and surface activation for fiber–matrix adhesion. The proposed chemical recycling pathway is operationally simple and cost-effective, produces reusable CFs with preserved graphitic structure and enhanced surface chemistry, and enables the fabrication of high-performance, waste-derived PLA composites suitable for structural and engineering applications. This work demonstrates a viable waste-to-value approach that advances circularity for both CFRP and 3D-printing polymer waste streams. Full article

The in-plane shear performance of carbon fiber-reinforced polymer (CFRP) composites is critical for structural design but is challenged by significant property scatter. This study aims to achieve individualized prediction of the complete shear stress–strain curve for each composite specimen using only a single early-stage digital image correlation (DIC) strain field. Systematic in-plane shear tests were conducted on 45 laminated carbon fiber/epoxy specimens with synchronized full-field DIC data and macroscopic load–displacement records. A lightweight encoder–decoder convolutional neural network was developed, taking a single DIC strain contour map at 0.2% global strain as input and mapping it directly to the full-range stress–strain curve up to failure for that specific specimen. Data augmentation and Dropout regularization mitigated the small-sample challenge. The proposed model achieved strong predictive performance across the five-fold cross-validation yielded a mean R² of 0.926 ± 0.022 and a mean RMSE of 6.37 ± 1.14 MPa for stress. Individual specimen predictions on the test set yielded an average R² of 0.945, with a minimum of 0.821, confirming robust capability across scattered properties. Residual analysis elucidated error characteristics across deformation stages. This research provides a novel paradigm for non-destructive, early-stage individualized assessment of composite mechanical properties, with applications in structural health monitoring and probabilistic design. Full article

Fibre-reinforced polymer composites incorporating synthetic reinforcements such as glass and carbon fibres are widely used due to their superior mechanical performance. However, their energy-intensive production and end-of-life disposal contribute to an increased carbon footprint and significant environmental burden. Natural fibre-reinforced composites have emerged as promising low impact alternatives, but variability in their mechanical performance and the lack of controlled comparative studies limit their structural application. This study presents a controlled experimental comparison of alkaline-treated unidirectional flax/epoxy and hemp/epoxy composites fabricated using the vacuum-assisted resin infusion moulding (VARIM) process. Alkali treatment was employed to enhance the fibre–matrix interfacial bonding. Mechanical characterization was conducted through tensile, flexural, impact, interlaminar shear strength (ILSS), and Vickers microhardness testing in accordance with relevant ASTM and ISO standards. The flax/epoxy composites exhibited superior in-plane mechanical performance including, 9.1% higher tensile modulus, 13.8% higher flexural strength and 20.5% higher flexural modulus compared to hemp/epoxy composites. A significant improvement was observed in impact performance, with hemp composites showing 87.4% higher impact strength, indicating enhanced resistance to dynamic loading. Conversely, hemp/epoxy composites demonstrated a 10.6% higher ILSS, suggesting improved interfacial shear resistance and fibre interlocking. These findings confirm that the fibre type significantly influences composite performance, with flax fibres providing superior stiffness and strength, while hemp fibres offer better interlaminar shear behaviour and impact strength. Scanning Electron Microscopy (SEM) fractographic analysis was additionally conducted on fracture surfaces to characterize failure mechanisms and fibre–matrix interfacial morphology. The present study provides a reliable comparative framework for material selection and demonstrates the potential of flax- and hemp-based composites as sustainable alternatives for lightweight structural applications. This study supports the development of sustainable composite materials and contributes to the United Nations Sustainable Development Goals (SDGs), particularly SDG 12 (Responsible Consumption and Production), SDG 13 (Climate Action), and SDG 11 (Sustainable Cities and Communities). Full article

High-speed permanent magnet synchronous motors (PMSMs) used in electric pump-fed liquid rocket engines require stator shielding sleeves to prevent corrosive propellants from causing harm under cyclic pressure. However, metallic sleeves suffer significant losses due to eddy currents. Conversely, pure carbon fiber reinforced polymer (CFRP) sleeves have failed when exposed to 98% H₂O₂. Micro-CT analysis of a failed pump sleeve reveals a four-stage failure mechanism. Manufacturing defects caused matrix cracking, which propagated under pressure and thermal cycling. This progression resulted in the formation of through-thickness leakage paths, which ultimately triggered catalytic decomposition and explosion. To address these issues, an improved dual-layer sleeve is proposed, featuring a 2.5 mm PEEK 450G liner and a 2.0 mm T700S/epoxy CFRP overwrap. Finite Element Analysis (FEA) indicates peak von-Mises stresses of 86.25 MPa and 112.16 MPa, yielding Tsai–Wu safety factors of 2.9 and 1.7. Furthermore, various tests, including immersion, fatigue, burst, hydraulic, and thermal evaluations, demonstrate a burst margin of 2.37× at 7.12 MPa, with only 0.19% increase in mass. This design effectively eliminates leakage pathways while preserving zero eddy-current loss and ensuring a low weight. Full article