Search Results (250)

Carbon fiber-reinforced polymer (CFRP) composites are widely used in aerospace due to their excellent strength-to-weight ratio and tailorable properties. However, these properties critically depend on the CFRP curing cycle. The commonly adopted manufacturer-recommended curing cycle (MRCC), designed to accommodate the most conservative conditions, involves prolonged curing times and high energy consumption. To overcome these limitations, this study proposes an efficient and adaptable method to determine the optimal curing cycle. The effects of varying heating rates on resin dynamic and isothermal–exothermic behavior were characterized via reaction kinetics analysis using differential scanning calorimetry (DSC) and rheological measurements. The activation energy of the reaction system was substituted into the modified Sun–Gang model, and the parameters were estimated using a particle swarm optimization algorithm. Based on the curing kinetic behavior of the resin, CFRP compression molding process orthogonal experiments were conducted. A weighted scoring system incorporating strength, energy consumption, and cycle time enabled multidimensional evaluation of optimized solutions. Applying this curing cycle optimization method to a commercial epoxy resin increased efficiency by 247.22% and reduced energy consumption by 35.7% while meeting general product performance requirements. These results confirm the method’s reliability and its significance for improving production efficiency. Full article

The increasing need for materials that are both lightweight and strong in the aerospace and automotive sectors has driven the extensive use of composite sandwich structures. This study examines the impact response of honeycomb sandwich composites fabricated using the vacuum-assisted resin transfer molding (VARTM) technique. Two configurations were analyzed, namely carbon–honeycomb–carbon (CHC) and carbon–Kevlar–honeycomb–Kevlar–carbon (CKHKC), to assess the effect of Kevlar reinforcement on impact resistance. Charpy impact testing was conducted to evaluate energy absorption, revealing that CKHKC composites exhibited significantly superior impact resistance compared to CHC composites. The CKHKC composite achieved an average impact strength of 70.501 KJ/m², which is approximately 73.8% higher than the 40.570 KJ/m² recorded for CHC. This improvement is attributed to Kevlar’s superior toughness and energy dissipation capabilities. A comparative assessment of impact energy absorption further highlights the advantages of hybrid Kevlar–carbon fiber composites, making them highly suitable for applications requiring enhanced impact performance. These findings provide valuable insights into the design and optimization of high-performance honeycomb sandwich structures for impact-critical environments. Full article

This study consisted of the injection molding simulation of polycaprolactone (PCL)-based nanocomposites reinforced with multi-walled carbon nanotubes (MWCNTs) for biomedical implant manufacturing. The simulation was additionally supported by experimental validation. The influence of varying MWCNT concentrations (0.5%, 5%, and 10% by weight) on key injection molding parameters, i.e., melt flow behavior, pressure distribution, temperature profiles, and fiber orientation, was analyzed with SolidWorks Plastics software. The results proved the low CNT content (0.5 wt.%) to be endowed with stable filling times, complete mold cavity filling, and minimal frozen regions. Thus, this formulation produced defect-free modular filament sticks suitable for subsequent 3D printing. In contrast, higher CNT loadings (particularly 10 wt.%) led to longer fill times, incomplete cavity filling, and early solidification due to increased melt viscosity and thermal conductivity. Experimental molding trials with the 0.5 wt.% CNT composites confirmed the simulation findings. Following minor adjustments to processing parameters, high-quality, defect-free sticks were produced. Overall, the PCL/MWCNT composites with 0.5 wt.% nanotube content exhibited optimal injection molding performance and functional properties, supporting their application in modular, patient-specific biomedical 3D printing. Full article

The manufacturing methodologies for carbon fiber triaxial woven fabric composites demonstrate significant variability, resulting in the failure mechanisms under tensile loading conditions, and the fundamental role of interweaving points remains unclear. Moreover, the mechanisms of destruction under tensile loads have not been sufficiently studied. In this study, the resin transfer molding and resin film infusion were selected to fabricate carbon fiber triaxial woven fabric composites, with a specific focus on their effects on the tensile properties of carbon fiber triaxial woven composites. Compared with ordinary materials, the tensile load of carbon fiber triaxial woven fabric composites after yarn spreading has increased by more than 30%. The strength can reach 1133 MPa after yarn spreading of 3k carbon fiber, which was 39% higher than the original. Furthermore, acoustic emission monitoring shows that the counts of acoustic signals in the first half dropped from 10,000 to around 3000, mostly due to the reduction of resin and fiber/matrix debonding. The digital image correlation provided full-field strain analysis, which proved that the strain of the fibers at the interweaving points decreased significantly during the stretching process after yarn spreading. Full article

In the composite materials industry, the fabrication of complex parts often necessitates the use of specialized tools, such as milled molds with intricate geometries. Among these, machined aluminum molds are widely regarded as effective tools for laminating CFRP (Carbon Fiber Reinforced Polymer) prepreg materials. However, the cost and time associated with machining aluminum molds can be significant. This paper presents a novel method for manufacturing molds using polymeric acrylic resin combined with aluminum trihydrate material (commercially known as DuPont Corian materials), offering a potential alternative with reduced complexity and cost. The study investigates the influence of various milling parameters, such as tool speed, tool type, feed rate, and depth of cut on the mechanical properties and surface finish of the molds. Also, laminating tests are conducted; results indicate that laminating tools produced through this method achieve competitive mechanical performance, including a hard, smooth surface with low roughness, making them viable candidates for industrial use. The proposed approach is particularly beneficial in terms of reducing machining time and overall costs while maintaining the necessary precision and durability for high-performance applications. This method, therefore, represents a promising solution for manufacturers seeking to optimize mold production processes in the composite materials industry. Full article

Jointing is inevitable for CFRTP (carbon fiber reinforced thermoplastic) component applications in the automotive industry. In this study, commonly used jointing methods were applied to fasten CFRTP components. Three types of jointing methods. Ultrasonic welding, bolted joints, and adhesive joining, and three types of CFRTP materials, conventional cross-ply, ultra-thin prepreg cross-ply, and sheet molding compounds, were selected. The influence of the jointing methods on mechanical properties and damage patterns under bending load has been investigated. The finite element models were developed to predict the hazardous area and structural stiffness of jointed structures; the simulation results showed good agreement with experimental ones. The results indicate that the ultrasonic welding could reach similar bending stiffness compared to adhesive joining, whereas the stiffness of bolt jointed structures is relatively lower due to the contact separation induced by the bending deformation. Overall, the finite element model results correlated well with the experimental data. Full article

High-performance discontinuous carbon-fiber-reinforced thermoplastics (CFRTPs) offer promising manufacturing flexibility and recyclability for advanced composite applications. However, their mechanical performance and reliability strongly depend on the internal fiber architecture, which is largely determined by the molding process. In this study, three distinct compression molding approaches—CFRTP sheet molding compounds (SMCs), bulk molding compounds (BMCs), and free-edge molding compounds (FMCs)—were systematically evaluated to investigate how processing parameters affect fiber orientation, tape deformation, and impregnation quality. X-ray micro-computed tomography (XCT) was employed to visualize and quantify the internal structures of each material, focusing on the visualization and quantification of in-plane and out-of-plane fiber alignment and other internal structure features. The results indicate that CFRTP-SMC retains largely intact tape layers and achieves better impregnation, leading to more uniform and predictable internal geometry. Although CFRTP-BMC exhibits greater tape deformation and splitting due to increased flow, its simpler molding process and better tolerance for tape shape distortion suggest potential advantages for recycled applications. In contrast, CFRTP-FMC shows significant tape fragmentation and poor impregnation, particularly near free edges. These findings underscore the critical role of a controlled molding process in achieving a consistent internal structure for these materials for the first time. This study highlights the utility of advanced XCT methods for optimizing process design and advancing the use of high-performance discontinuous CFRTP in industry. Full article

This study investigates the use of carbonized hemp fiber (CHF) as a reinforcement for phenol resorcinol formaldehyde (PRF)-based fiber composites. The hemp fiber was carbonized slowly up to 1000 °C under N₂ with a yield of 18%. Compression-molded composites were prepared with CHF and then compared to hemp (HF) and wood fiber (WF) at 0 to 50% loading with PRF resin. The flow characteristics of the uncured composites were determined by dynamic rheology and showed pseudoplastic behavior; the composites show promise as extrudable materials. The flexural strength of the HF composites (69 MPa for 40% HF) was higher than the CHF composites. The thermal stability of the composites was determined by thermogravimetric analysis (TGA), and the CHF composites were more stable than the HF and WF composites. Carbonization was shown to enhance both the thermal stability and the hydrophobicity of the composites, which is expected to lead to less susceptibility to weathering and biological attack. Formulations of 50% WF, 50% CHF, and 30% HF fiber loadings with PRF were able to be extruded into rods. Extruded CHF composites showed better mechanical properties than the HF and WF composites. Full article

The properties of composite materials depend not only on the composition but also on the distribution and orientation of the fillers, i.e., on the internal material architecture. Using the example of two differently composed PEEK-based hybrid materials, the influence of fiber orientation on the tribological behavior of these materials in sliding contact with steel was investigated. The tribological performance of these composites was assessed using a pin-on-disc (PoD) tribometer, testing in a pv range from 0.25 to 32 MPa·m/s. The findings indicate that the printed specimens exhibit a high degree of fiber orientation aligned parallel to the printing paths. Conversely, the injection-molded samples display a three-layered structure across the thickness, with fibers in the skin layers aligned parallel to the injection direction but perpendicular to it in the core. These variations in morphology are evident in both the mechanical properties and the tribological behavior. To describe the influence of the fiber orientation on tribological properties, a model is proposed that allows the prediction of tribological properties for any fiber orientation. Although fiber orientation appears to be the dominant factor in tribological behavior, there is also a clear influence of additional fillers. Full article

Thermal protection materials with excellent performance are critical for hypersonic vehicles. Carbon fiber/phenolic resin composites (C_f/Ph) have been widely used as thermal protection materials due to their high specific strength and ease of processing. However, oxidative failure limits the extensive applications of C_f/Ph in harsh environments. In this paper, a novel hafnium carbide (HfC) and boron carbide (B₄C)-modified C_f/Ph was fabricated via an impregnating and compression molding route. The synergistic effect of HfC and B₄C on the thermal stability, flexural strength, microstructure, and phase evolution of the ceramizable composite was studied. The resulting ceramizable composites exhibited excellent resistance to oxidative corrosion and ablation behavior. The residual yield at 1400 °C and the flexural strength after heat treatment at 1600 °C for 20 min were 46% and 54.65 MPa, respectively, with an increase of 79.59% in flexural strength compared to that of the composites without ceramizable fillers. The linear ablation rate (LAR) and mass ablation rate (MAR) under a heat flux density of 4.2 MW/m² for the 20 s were as low as −8.33 × 10⁻³ mm/s and 3.08 × 10⁻² g/s. The ablation mechanism was further revealed. A dense B–C–N–O–Hf ceramic layer was constructed in situ as an efficient thermal protection barrier, significantly reducing the corrosion of the carbon fibers. Full article

The use of natural fibers in hydro turbine rotors promotes sustainability by offering biodegradable, renewable materials with a lower carbon footprint. This study compares the hydrodynamic performance of two rotors in a gravitational vortex turbine: Rotor 1, 3D-printed with polylactic acid (PLA), and Rotor 2, made from fique fiber and epoxy resin using manual molding. To compare the rotors, experimental tests were conducted on a laboratory-scale setup, where the behavior of both rotors was evaluated under different flow regimes. Rotor 1 achieved 61.01% efficiency at an angular velocity ($\omega$) 160 RPM, while Rotor 2 reached only 19.03% at $\omega$ of 165 RPM. The lower performance of Rotor 2 was due to dynamic imbalances and mechanical vibrations, leading to energy losses. These challenges highlight the limitations of manual molding in achieving precise rotor geometry and balance. To improve natural fiber rotor viability, optimizing manufacturing techniques is crucial to enhance dynamic balance and minimize vibrations. Advancements in fabrication could bridge the performance gap between natural and synthetic materials, making bio-based rotors more competitive. This study emphasizes the potential of natural fibers in sustainable energy and the need to refine production methods to maximize efficiency and reliability. Addressing these challenges will help integrate eco-friendly rotors into hydro turbine technologies. Full article

Recycling carbon-fiber-reinforced plastics (CFRPs) is crucial for sustainable material utilization, particularly in aerospace applications, where large quantities of prepreg waste are generated. This study investigated the mechanical properties of highly oriented recycled CFRP (rCFRP) molded using vacuum-assisted resin transfer molding (VaRTM), wet-layup, and traditional RTM methods. Recycled carbon fibers (rCFs) obtained via solvolysis and pyrolysis were processed into nonwoven preforms to ensure fiber alignment through carding. The influence of molding methods, fiber recycling techniques, and fiber orientation on mechanical performance was examined through tensile tests, fiber volume fraction (Vf) analysis, and scanning electron microscopy observations. The results indicated that the solvolysis-recycled rCF exhibited superior interfacial adhesion with the resin, leading to a higher tensile strength and stiffness, particularly in the RTM process, where a high Vf was achieved. Wet-layup molding effectively reduced the void content owing to autoclave curing, maintaining stable properties even with pyrolyzed rCF. VaRTM, while enabling vacuum-assisted resin infusion, exhibited a higher void content, limiting improvements in mechanical performance. This study highlights that tailoring the molding method according to the desired performance, such as increasing stiffness potential by enhancing Vf in RTM or improving tensile strength by improving fiber–matrix adhesion in wet-layup molding, is critical for optimizing rCFRP properties, providing important insights into sustainable CFRP recycling and high-performance material design. Full article

SCF/PA6 composites have gained extensive industrial applications due to their superior processability and moldability, with long-fiber pellet injection molding being the predominant manufacturing technique. However, systematic investigations into injection molding parameter optimization and its mechanistic impacts on tensile strength remain scarce. This study employed the Taguchi method to investigate the effects of four critical process parameters—injection pressure, melt temperature, mold temperature, and injection time—on the tensile strength of short-carbon-fiber-reinforced nylon 6 (SCF/PA6), while elucidating their underlying mechanisms. The optimal parameter combination within the experimental range was determined to be an injection pressure of 100 bar, a melt temperature of 280 °C, a mold temperature of 100 °C, and an injection time of 2 s. Under these optimized conditions, the tensile strength reached 184.33 MPa, representing an 8.05% enhancement over baseline values. Mechanistic analysis revealed that melt temperature and injection time (essentially reflecting injection velocity) primarily govern fiber orientation distribution. Notably, melt temperature additionally regulates molecular chain orientation in the amorphous matrix regions. Injection pressure predominantly influences process-induced defect formation and material densification. Mold temperature exhibits a negligible impact on tensile strength. Full article

Additive manufacturing has reached a level of reliability and credibility that has already been integrated into specific industries producing final parts or tooling. Among Material Extrusion (ME) techniques, the Fused Granular Fabrication (FGF) method has enabled the development of Large Format Additive Manufacturing (LFAM) using polymeric materials, which has also established its presence in industries working with large prototypes, molds, and tools. This cost-efficient process has proven its applicability and success in manufacturing molds for composites, particularly in short and medium production runs, significantly reducing production times and costs. This paper presents two experiments designed to optimize process parameters when producing molds using the combined FGF and milling approach. These experiments identified optimal extrusion temperatures and extrusion multipliers to minimize defects at both the macro- and microscales for ASA 20 wt.% carbon fiber (CF) material; additionally, a correlation between milling speed, milling strategy, and surface roughness was established. These findings are valuable for industries adopting this innovative production method, as they provide guidance for defining process parameters to achieve the desired surface roughness of a specific part. A case study of the design of an automobile carter mold is presented, concluding that a specific range of milling speeds is required for conventional or climbing milling strategies to achieve a defined surface roughness range. Full article

This study introduces a methodology for characterizing and modeling the viscosity and specific volume–pressure–temperature (pvT) behavior of sheet molding compound (SMC) materials, based on the use of specialized testing equipment. Conventional rheometers are inadequate for such materials due to the presence of long fibers, necessitating the use of specialized equipment like squeeze flow rheometers and pvT dilatometers. Our findings demonstrate that traditional oscillatoric rheometer measurements underestimate the viscosity of CF-SMCs, highlighting the need for advanced, albeit non-standardized, testing methods. Additionally, we found that standard Tait models failed to capture the temperature-dependent porosity of CF-SMCs at low pressures, whereas models based on thermodynamic state variables (TSVs) provided accurate predictions across a broader range of conditions. The study also addressed the complexities introduced by fiber–flow coupling and the fiber orientation in measuring the viscosity, revealing limitations in conventional modeling approaches. The numerical analysis showed that a power law-based anisotropic viscosity model (PL-IISO) combined with a TSV model offered the best predictive performance in finite volume flow simulations, especially for thick-walled regions. However, the current modeling approaches have limited predictive capabilities for the fiber orientation in thin-walled regions. This research underscores the challenges in accurately modeling CF-SMC materials in terms of the fiber orientation, whereas the compression forces needed from the pressing machine could be predicted accurately within an average error of 6.5% in the squeeze flow experiments. Full article