Search Results (1,876)

Carbon-fiber-reinforced polymer (CFRP) composites are widely used in lightweight aerospace structures because their mechanical performance can be adapted to different structural requirements through appropriate manufacturing conditions. This study investigates the influence of curing temperature applied using temperature-controlled heated molds on the mechanical and thermo-mechanical behavior of vacuum-infused CFRP laminates manufactured with an IN2 epoxy infusion resin. Laminates were cured at room temperature (25 °C) and at 40, 50, 60, and 70 °C using heated molds. Their performance was evaluated by tensile testing, three-point bending, and heat deflection temperature (HDT) measurements. The highest tensile strength (675.06 MPa) was obtained for laminates cured at 40 °C, whereas increasing the curing temperature beyond this value did not provide further improvement in tensile performance. The highest flexural stress at the first peak (983.36 MPa) and flexural modulus (67.17 GPa) were obtained for laminates cured at 70 °C, while the highest energy absorption during bending (0.57 J) was measured for laminates cured at 40 °C. The HDT increased from 59.77 °C for room-temperature curing to 87.60 °C for laminates cured at 70 °C, indicating improved thermo-mechanical stability with increasing curing temperature. The results indicate that no single curing temperature simultaneously maximized the tensile, flexural, and thermo-mechanical properties. Instead, the optimum curing temperature depended on the specific mechanical and thermo-mechanical requirements of the intended application. The results further indicate that controlling the temperature of heated molds during manufacturing provided a practical approach for tailoring the mechanical and thermo-mechanical performance of CFRP laminates without modifying the reinforcement architecture, laminate stacking sequence, or constituent materials. Full article

Today, the search for resources related to non-fossil raw materials that require less carbon-based energy consumption, use less water, and produce recyclable waste is prevailing. In the future, will this effort be replaced by resources sufficient to be produced in environmentally friendly ways? Resources will be circulated in a controlled manner, and materials will be sustainable. Most of the energy sources will be sustainable, derived from natural resources (sun, wind, waves, geothermal sources, etc.). The world will be managed by data, enabling resource sufficiency. Sustainable development is therefore a long-term strategy including economic, human (social), and environmental (material) resources. This strategy requires development in the complex identification and quantification of waste of different origins, including plastics and fibers. The identification of polymer complex mixtures and fibrous-blend waste, including microplastics, is a fundamental tool for effective environmental monitoring and comprehensive recycling management. Raman spectroscopy, combined with spectral unmixing techniques, provides a powerful tool for resolving overlapping spectral components and characterizing the composition of fibrous polymeric materials. The general goal of hyperspectral unmixing is to decompose an observed spectral mixture matrix into a set of pure component spectra and their respective portions (contributions or abundance) or ideally concentrations. This requires solving an inverse problem under physical and mathematical constraints. Principal component analysis (PCA), based on singular value decomposition (SVD), followed by independent component analysis (ICA) rotation, is used to reduce the number of components to a meaningful set of endmembers. The extracted endmembers should be statistically independent, nonnegative, and sum to one, because they represent real chemical components in the mixture. These requirements are fulfilled by constrained quadratic programming using the Newton linearization method. The RAMIX program, based on these procedures, has already been described, and its source code is available in another article written in Python. It is designed for the analysis of experimental Raman spectra of polymeric mixtures and for mapping waste fibrous blends. This program is used here for Raman spectral analysis of compressed textile samples composed of different staple fiber types. To evaluate Raman spectra, a simple, cost-effective, custom-built measurement system was created. This system allows mapping of fibrous mixtures by Raman spectra across a line or an area. Full article

The increasing adoption of additive manufacturing in the construction sector has intensified the demand for lightweight, recyclable cement-based composites with low environmental impact, suitable for automated 3D printing. Foamed concrete reinforced with dispersed fibers and incorporating recycled constituents represents a promising class of multifunctional materials. However, its environmental performance remains insufficiently characterized. This study provides a comprehensive evaluation of thermal stability, leaching behavior, and microbial resistance of 3D-printable fiber-reinforced foamed cement composites produced with recycled components. Thermogravimetric–Fourier transform infrared (TG–FTIR) analysis confirmed a characteristic three-stage thermal decomposition pathway typical of hydrated cementitious systems. All composites exhibited high thermal stability, with residual masses of 88.56–90.17% at 900 °C. The binder type exerted a stronger influence on decomposition behavior than atmospheric exposure or freeze–thaw conditioning. Leaching tests revealed strongly alkaline eluates (pH 11.0–11.4), low total organic carbon (<0.6 wt.%), and only trace concentrations of BTEX (35–41 μg/kg), PAHs, and PCBs. Alkali activation increased the release of chromium (3.6–4.0 mg/kg), arsenic (1.2 mg/kg), copper (4.5 mg/kg), antimony (0.26 mg/kg), and sulfates (2700–4700 mg/kg), accompanied by elevated total dissolved solids (~18,000 mg/kg). Nevertheless, all environmentally relevant constituents remained well below the waste acceptance criteria (WAC), confirming effective immobilization of hazardous species within the hardened matrix. The results provide new insights into the relationships among material composition, porous microstructure, and environmental safety, demonstrating that the developed 3D-printable foamed composites exhibit robust performance, suitability for safe and durable applications, and favorable environmental performance. Full article

Tailored flax-reinforced composites (TFRC) are being investigated as a sustainable alternative to conventional glass- and carbon-fiber-reinforced composites, having a lower fiber volume than these and the structure of the laminate with two plies (two identical layers of alkali-treated flax yarns) is unidirectional, weakly twisted, oriented at ±45°, and reinforced by stitching; it is also impregnated with bio-resin and has robust reinforcement through controlled lamination. TFRC has shear-dominated behavior under both tensile and compressive loading, due to the off-axis orientation of the fibers, but the damage evolution differs significantly. Under tensile loading, the material exhibits a lower strength (55.2 MPa), whereas under compression loading, the composite achieves a higher apparent strength (99.1 MPa). The paper provides a comprehensive analysis for structural and mechanical characterization using the following: nondestructive evaluation using ultrasound to detect internal discontinuities and assess homogeneity; optical microscopy to evaluate fiber–matrix integration and porosity reduction; and Dynamic Mechanical Analysis to assess thermomechanical transitions and storage modulus stability. Finite element simulations have been used to determine elastic properties and validate the matrix-dominated shear response. The results confirm that the [±45°]_4S sequences of TFRC optimize mechanical response and interfacial adhesion, promoting TFRC as an ecological solution for structural systems where progressive energy dissipation is preferred. Full article

AZ91D is a lightweight, representative commercial magnesium alloy known for its excellent castability and specific strength. However, the mechanical properties of as-cast AZ91D remain limited by inherent brittleness, relatively low strength, and microstructural inhomogeneity caused by enrichment of secondary phases at grain boundaries. In this study, AZ91D/Csf (short carbon fiber at 0, 2.5, and 5 wt.%) composites were prepared by gravity casting with mechanical stirring, followed by post-casting T4 heat treatment and equal-channel angular pressing (ECAP). Material characterization included optical microscopy (OM), field-emission scanning electron microscopy (FESEM), energy-dispersive spectroscopy (EDS), X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), uniaxial tensile testing, and microhardness tests. The results demonstrate that T4 treatment reduced intermetallic β-Mg₁₇Al₁₂ segregation and homogenized the microstructure, whereas one-pass ECAP further refined the grains. Mechanically, these two processes enable the (AZ91D/5 wt.% Csf) composite to achieve higher ultimate tensile strength (280.7 MPa by T4/280.2 MPa by T4 + one-pass ECAP), larger maximum strain (12.1% by T4/5.4% by T4 + one-pass ECAP), and higher microhardness (63.9 HV by T4/78.1 HV by T4 + one-pass ECAP). Compared to as-cast AZ91D, these findings demonstrate that T4 treatment provides a better strength–ductility balance via solid solution, whereas one-pass ECAP preferentially enhances surface microhardness by plastic deformation. This study highlights the performance of AZ91D/Csf composites and their potential for lightweight, high-strength-demand applications. Full article

The rapid expansion of fiber-reinforced polymers (FRPs) in wind energy, transportation, and aerospace is generating increasing amounts of accompanied waste, making effective valorization essential to a circular economy. This review compares FRP recovery technologies in terms of recovered-fiber quality, operating conditions, post-treatment, environmental impacts, and industrial applicability. Then, it also examines direct reuse, FRP remanufacturing, and reuse in cementitious composites. Quantitative synthesis indicates that high-quality recycled carbon fibers (rCFs) generally retain more than 90% of their original strength, whereas mechanically recovered glass fibers (rGFs) typically retain approximately 70–90%. The preferred pathway depends on the intrinsic value, damage state, morphology, and residual properties. Components with sufficient residual capacity should be directly reused; high-quality fibers are better suited to polymer remanufacturing; and heterogeneous or lower-grade glass-FRP (GFRP) fractions are more compatible with cementitious applications, where mechanically recycled GFRP can provide interfacial bond strengths comparable to conventional engineering macrofibers. Future research should establish quantitative links among recovered material quality, processing, interfacial behavior, and end-use performance, while adopting consistent environmental and economic assessment boundaries. A graded utilization framework is therefore required to support both large-scale and value-added reuse of FRP waste. Full article

This study develops an integrated Analytic Hierarchy Process (AHP) and Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) multi-criteria decision-making (MCDM) framework to systematically evaluate and rank composite material combinations based on 24 fibers (16 natural and 8 synthetic), 15 matrices (thermosets, thermoplastics, and biopolymers), and 9 fiber volume fractions (30–70%) for UAV inlet applications. Ten evaluation criteria covering technical performance, environmental sustainability, and economic viability were weighted using AHP pairwise comparisons based on Saaty’s 1–9 scale, yielding a consistency ratio of CR = 0.009, which confirms the reliability of the judgments. The TOPSIS analysis identified Carbon (PAN-HM)/Epoxy as the optimal composite material, achieving the highest TOPSIS score of 0.8893. In contrast, Flax/Epoxy emerged as the best natural fiber composite, with a TOPSIS score of 0.2686, indicating a performance gap of approximately 231% in favor of the synthetic composite. Comprehensive sensitivity analysis across four weighting scenarios (Equal, Technical, Environmental, and Economic) confirmed the stability of the reinforcement rankings, with Carbon (PAN-HM) remaining the top synthetic fiber and flax the top natural fiber across all scenarios. The findings contribute to the growing body of knowledge on sustainable aerospace materials and provide practical guidance for UAV designers seeking to optimize material selection for micro-turbojet engine inlet components, supporting the development of more environmentally responsible UAV designs while maintaining the performance requirements for safe and reliable operation. Full article

The issue of near-field electromagnetic interference (EMI) is being made worse by the widespread use of highly integrated electronic devices, including commercial LED displays. Although highly conductive pristine carbon networks, like recycled carbon fiber nonwovens (rCFNWs), have excellent far-field shielding effects (~43 dB) in theory, their purely reflection-oriented mechanisms cause severe secondary signal interference in practical near-field applications due to reflective inefficiency. This study suggests employing a custom-formulated silicone-carbon nanotube (Si-CNT) composite to switch to an absorption-based shielding mechanism in order to get around these restrictions. This study used FE-SEM, Raman spectroscopy, XPS, ICP-AES, FTIR, and TGA-DTG to systematically investigate the morphological, chemical, and thermal properties of the rCFNW, Si-CNT composite, and a Cu-integrated variant (Si-CNT-Cu). Surface reflection was greatly reduced by adding CNTs to the silicone matrix, converting the materials into absorption-oriented localized shielding composite materials (~16 dB). Both the designed Si-CNT membrane and the Cu-integrated Si-CNT-Cu product totally eliminated the 850 MHz switching noise peak (>40 dBuV) in real near-field tests of commercial LED modules running under worst-case conditions (5.36 A). Additionally, the bare Si-CNT membrane showed a lower coefficient of thermal expansion (CTE) in the thermomechanical analysis (TMA) than the Si-CNT-Cu product. On the other hand, the macroscopic integration of Cu wires in the Si-CNT-Cu composite provided remarkable thermomechanical stability, preventing thermal softening by preserving an exceptionally high storage modulus of 97.54 MPa at 198 °C, according to dynamic mechanical analysis (DMA). These findings show that using absorptive suppression to overcome near-field inefficiency is a very successful method for creating dependable EMI shielding composite materials in high-power electronic systems. Full article

Battery packs for new energy vehicles have evolved from simple load-bearing and protective assemblies into multifunctional safety structures integrating structural support, crash protection, thermal-runaway mitigation, flame retardancy, electrical insulation, electromagnetic interference shielding, waterproof sealing, and long-term reliability. Fiber-reinforced polymer composites are promising for upper covers, underbody shields, trays, cross beams, side frames, and local protective structures because of their low density, corrosion resistance, design flexibility, and functional-integration potential. However, composite-part performance is strongly governed by forming. Resin flow, impregnation, curing or cooling shrinkage, fiber orientation, filler dispersion, and interfacial bonding may induce voids, dry spots, resin-rich regions, delamination, warpage, and fiber waviness, thereby affecting load bearing, sealing, thermal protection, and durability. This review focuses on composite-forming technologies for new energy-vehicle battery packs. It summarizes component-level service requirements and material systems and compares representative forming routes, including sheet molding compound (SMC), prepreg compression molding/wet compression molding (PCM/WCM), resin transfer molding/high-pressure resin transfer molding (RTM/HP-RTM), vacuum-assisted resin transfer molding (VARTM), long-fiber thermoplastic direct processing (LFT-D), glass-mat thermoplastic (GMT), thermoplastic sheet forming, pultrusion, and multi-material joining. These routes are evaluated from six dimensions: material form, forming cycle, typical defects, representative mechanical performance, applicable components, and engineering maturity. The review further discusses defect mechanisms, performance effects, detection and control methods, and the roles of in-line monitoring, non-destructive testing, process simulation, machine learning, and digital twins in closed-loop quality manufacturing. Finally, engineering challenges are examined in multi-material joining, thermal-safety integration, low-carbon recycling, and standard certification. Composite-material battery-pack structures should therefore be developed as coordinated design and closed-loop manufacturing systems linking materials, processes, defects, performance, and validation. Full article

A polyurea-coated carbon fiber reinforced plastic (CFRP) laminated structure is designed to enhance the impact resistance of lithium-ion batteries against ground impact. This paper presents a numerical simulation to investigate the influence of a polyurea-coated CFRP battery pack bottom plate on mitigating battery damage under ground impact conditions. A novel three-dimensional finite element model of the polyurea-coated CFRP laminate, incorporating a hyper-viscoelastic material model for the polyurea coating and an orthotropic model for the CFRP, is established to analyze the impact response and damage behavior of the laminate. The simulated impact peak force, energy absorption, and maximum crack length of the polyurea-coated CFRP laminate are all within 5% of the experimental results. Based on this validated three-dimensional model, a new battery pack simulation model is developed. The battery module model innovatively adopts a hybrid approach that combines homogenized battery module models and detailed battery module models, enabling accurate simulation of localized cell damage and failure during collisions while significantly improving computational efficiency. The punching process after perforation of the polyurea-coated CFRP laminate, the subsequent crack propagation of the plate, and the local deformation modes of individual cells are clearly predicted by the global model. Battery shortening is recorded as an important indicator of internal short circuits and potential thermal runaway. A parametric study is carried out, and several underlying rules are revealed: the front coating method leads to a greater reduction in battery damage, and the stiffness–toughness interplay between the polyurea coating and the carbon fiber composite is identified as a critical factor governing battery damage. This study provides important insights for the design of protective structures for battery packs against ground impact. Full article

In the manufacturing of carbon fiber/epoxy composites, different stacking sequences have different effects on the void inside materials. In this paper, the double-vacuum-bag (DVB) process was utilized to fabricate laminates with different stacking sequences, including different angles, different thicknesses and plain weave prepregs, and the single-vacuum-bag (SVB) process was set as the control group. The void content of different laminates in the cross-section was counted by image analysis software, and material thickness, density, and fiber volume fraction were measured by experiments. Three-point bending and short-beam-shear tests were conducted to evaluate the material mechanical properties. The results show that the void contents of laminates prepared by the DVB process are all less than 1% with different stacking sequences, while the laminates manufactured by the SVB process contain a large number of voids inside. The density and fiber volume fraction of the DVB process are higher than those of the SVB process. In terms of mechanical properties, the flexural strength and interlayer-shear-strength (ILSS) of the DVB process are higher than those of the SVB process. The results of this paper expand the application of the DVB process and provide a reference for low-cost manufacturing of composite materials. Full article

Environmental sustainability of natural and synthetic fibers used in textiles and composites depends on their impacts throughout production, use, and end-of-life (EoL) stages. Natural fibers are renewable and biodegradable but may require substantial water and agricultural inputs, whereas synthetic fibers contribute to fossil resource depletion, microplastic pollution, and persistent waste generation. Natural fibers are often regarded as more sustainable alternatives to synthetic fiber; however, evidence from a life cycle assessment (LCA) reveals a more nuanced reality. As demand for fiber-based materials increases across textile and composite applications, a deeper understanding of the environmental implications of both natural and synthetic options becomes essential. This review compares these fiber categories from a life cycle perspective, examining carbon footprint, energy demands, resource consumption, and EoL pathways. Natural fibers such as cotton, flax, jute, hemp, sisal, banana, coir, and emerging plant-based alternatives offer advantages including biodegradability and carbon sequestration during cultivation. Nevertheless, agricultural practices and subsequent industrial processing require substantial land, water, and chemical inputs. Synthetic fibers, predominantly derived from fossil resources, provide a long service life and consistent performance but are associated with high greenhouse gas (GHG) emissions, dependence on non-renewable feedstocks, microplastic pollution, and broader environmental impacts. By presenting a comprehensive life cycle-based comparison, this review identifies the conditions under which each fiber type may offer environmental benefits, supporting informed material selection for sustainable development. Full article

Laminated carbon fiber reinforced polymer (CFRP) beams are widely used in lightweight structures, yet their vibration response depends strongly on laminate architecture, boundary conditions, thickness, and material anisotropy. Previous studies often examined these effects separately or relied on a single analytical or numerical approach. This study presents a multi fidelity framework integrating classical laminate theory (CLT), the Vinson–Sierakowski (VS) equivalent modulus method, and three-dimensional finite element analysis for modal prediction and parametric design of symmetric CFRP laminated beams. Three stacking sequences, [0/0/0/0], [0/45/45/0], and [0/90/90/0], were evaluated under clamped-free (CF) and clamped-clamped (CC) conditions. ANSYS models using quadratic HEX20 solid elements served as the numerical reference. Across 36 validation frequencies, the mean absolute percentage errors were 3.05% for CLT and 2.28% for VS, giving VS a 25.1% lower average error. The [0/0/0/0] laminate produced the highest frequencies. The first numerical frequency increased from 36.37 to 230.20 Hz when the boundary condition changed from clamped-free to clamped-clamped. Increasing thickness from 2 to 8 mm raised the first frequency from 18.20 to 72.62 Hz, while increasing $E_1/E_2$ from 10 to 30 raised it from 30.80 to 53.85 Hz. The framework supports rapid screening, laminate level interpretation, and detailed numerical verification for vibration-oriented composite beam design. Full article

Flexural strength (FS) governs the structural performance of 3D-printed concrete (3DPC) under bending loads yet remains difficult to predict owing to the coupled influence of binder composition, supplementary cementitious materials, water-to-binder ratio, and fiber reinforcement geometry on interlayer fracture behavior. Much of this compositional diversity stems from supplementary cementitious materials, industrial by-products whose reuse as partial cement replacement lowers the embodied carbon of printable mixes. A machine learning framework was trained on 209 FS records covering OPC- and SAC-based systems (FS: 3.65–45.0 MPa; W/B: 0.15–0.65). Six composite features were constructed from physical principles, two of them specific to bending: Fiber_Pullout_Index encoding post-crack pullout energy and Binder_Efficiency capturing cement quality per unit water content at the fiber–matrix interface; Lasso regularization with the one-standard-error rule reduced the 19-variable space to 14 active predictors. Twenty regression algorithms spanning eight families were benchmarked under 30 independent partitions; the Friedman test rejected equal performance (${\chi }^2=337.02$, $p=4.88\times {10}^{-60}$) and all 19 pairwise Wilcoxon comparisons against CatBoost were Holm-significant. CatBoost ranked first (mean rank of 18.17/20; 30-run $R^2=0.9302\pm 0.0722$; seed-42 partition: $R^2=0.9557$; RMSE = 1.761 MPa; MAPE = 11.20%). n(W/B) emerged as the primary driver across SHAP, ALE and LIME, with a monotonic ALE profile spanning 8.99 MPa and no inflection over the full printable window; Binder_Efficiency ranked second (PDP range: 5.21 MPa), isolating cement grade and paste dilution as independent strength levers. Cross-conformal prediction provided finite-sample coverage guarantees without distributional assumptions (empirical coverage: 95.24%; conformity quantile: 3.83 MPa); bootstrap analysis put the epistemic component at a mean predictive SD of 0.946 MPa, a quarter of that quantile. External validation yielded $R^2=0.769$ (Pearson $R=0.923$, RMSE = 1.91 MPa), with 19 of 20 predictions (95.0%) within Bland–Altman 95% limits of agreement, confirming transfer to a source study withheld from model training. A graphical user interface packaging the 14-feature CatBoost pipeline supports mix design queries without programming. Full article

The growing demand for low-carbon building materials and the challenges of handling agroforestry waste and discarded EPS particles have spurred research toward developing novel building composites that utilize solid waste. Therefore, this study aims to develop a lightweight geopolymer composite incorporating these recycled materials to balance thermal insulation, mechanical strength, and waterproofing properties. In this work, geopolymer served as the binder, with various types of raw biomass (sawdust, rice husk, rice straw, and coconut fiber) as the primary aggregates and EPS particles as an additive to create a closed-pore structure. The microstructure of the raw biomass was characterized by SEM, while its specific surface area and average pore diameter were determined by BET analysis. Furthermore, the prepared composites were comprehensively evaluated in terms of their microstructure, pore structure (MIP), density, thermal conductivity, compressive strength, total water absorption, capillary water absorption, surface wettability, and UV aging behavior. The results showed that the prepared composites exhibited a porosity of 59.9–65.7%, a density of 492.9–586.3 kg/m³, a compressive strength of 7.3–10.9 MPa, a thermal conductivity of 0.115–0.142 W/(m·K), a total water absorption of 35.2–42.2%, capillary water uptake coefficients of 4.9–11 kg/m², and a water contact angle exceeding 140° (after modification). In addition, the developed composites offered significant environmental and economic benefits, with a low carbon footprint and an estimated cost of 100.6–150.3 USD/m³, making them more competitive compared to traditional insulation materials. Meanwhile, this study provides a scientific basis for developing high-strength building insulation materials from agroforestry waste, thus outlining a promising direction for future research and industry development. Full article