Search Results (1,929)

Vehicle crush boxes are one of the safety elements used in vehicles to minimize damage that may occur during an accident. The task of crush boxes is to absorb the energy which is generated during an accident. In this study, peak force, energy absorption and specific energy absorption values of cylindrical composite crush boxes, to which 0.25% and 0.50% graphene was added, were experimentally investigated with hydrothermal aging. The composite crush boxes were produced with vacuum infusion method. Glass, aramid and carbon fibers and their hybridizations were used as fibers. During hybridization, the winding order of the fibers was changed from inside to outside. The parameters for hydrothermal aging were selected as 500 h and 1000 h at 60 °C. The highest energy absorption value was obtained in the carbon fiber-reinforced sample CFRPG1H2 with 0.25% graphene-added epoxy resin matrix, aged for 1000 h. The lowest peak strength was observed in the aramid fiber-reinforced sample AFRPG2H2 with 0.50% graphene-added epoxy resin matrix, hydrothermally aged for 1000 h. It was observed that increasing the graphene addition rate reduced the negative effects on aging. It was determined that increasing the graphene ratio by 0.25% had an effect on aging. Full article

The mechanical properties of carbon fiber composites (CFRCs) are governed by the carbon fibers (CFs) themselves and the fiber–matrix interface (FMI), with the synergy between the two being crucial. This study focused on how microstructural heterogeneity affects the compression after impact (CAI) of the same epoxy resin (EP) composites. The research was conducted using two variants of dry-jet wet-spun T800G CFs, labeled CF-low and CF-high. The results indicated that while CF-low exhibited a higher number of deep axial grooves and a greater surface micro-zone compressive modulus, their pronounced skin–core structure and the excessively strong interfacial bonding formed by mechanical interlocking aggravated fiber core collapse and stress concentration under mechanical loading. In contrast, the homogeneous structure and moderate interfacial characteristics of CF-high facilitated efficient stress transfer between the CFs and EP. Compared with CF-low composites, CF-high composites exhibited a 9% increase in CAI strength and a 35% reduction in damage area, significantly improving the damage tolerance of the composites. This research underscores that optimizing the synergy between the fiber properties and the interfacial behavior is key to enhancing CFRC performance. Full article

Fused Deposition Modeling (FDM) is a widely used additive manufacturing technique that enables the fabrication of components using polymeric and composite materials; however, the mechanical performance of printed parts is jointly influenced by multiple printing parameters, which complicates the control and prediction of their mechanical properties. In this study, an attention-enhanced multi-modal convolutional neural network (ATT-MM-CNN) is developed to predict the tensile performance of carbon fiber reinforced polylactic acid (PLA-CF) composites manufactured by FDM. Four key printing parameters, layer thickness, nozzle temperature, material flow rate, and printing speed, are systematically investigated, resulting in 256 parameter combinations and corresponding tensile test data for constructing a multi-modal dataset. By integrating multi-modal feature representations and incorporating an attention mechanism, the proposed model effectively learns the nonlinear relationships between printing parameters and mechanical performance under multi-parameter conditions. The results show that all evaluation metrics, including accuracy, precision, recall, and F1-score, exceed 0.95, and the prediction accuracy is improved by at least 17.3% compared with baseline models. These findings demonstrate that the proposed ATT-MM-CNN provides an effective and reliable framework for tensile property prediction and process-parameter optimization of FDM-printed composite structures. Full article

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

Polymer composites have opened a novel innovation phase in additive manufacturing (AM), and now lightweight, high-strength, and geometrical advanced components with tailored functionalities can be produced. The present study introduces advances in polymer composite materials and their integration into AM processes, particularly in rapidly growing industries such as aerospace, automotive, biomedical, and electronics. The embedding of cutting-edge reinforcement materials, such as nanoparticles, carbon fibers, and natural fibers, into polymer matrices enhances mechanical, thermal, electrical, and multifunctional properties. These material developments are combined with advanced fabrication techniques, including multi-material printing, in situ curing, and functionally graded manufacturing, which achieves accurate regulation of microstructures and properties. Furthermore, high-impact innovations such as smart polymer composites with self-healing or stimuli-responsive behaviors, the growing shift toward sustainable, bio-based composite alternatives, are driving progress. Despite significant advances, challenges remain in interfacial bonding, printability, process repeatability, and long-term durability. This review offers a comprehensive overview of current advancements and outlines future directions in polymer composite–based AM. Full article

Façades account for approximately 15–20% of a building’s embodied carbon, making them a key target for material decarbonization. While bio-composites are increasingly explored for façade insulation, cladding systems remain dominated by carbon-intensive materials such as aluminum and fiber-reinforced polymers (FRPs). This paper presents findings from a study investigating the use of food-waste-derived bulk fillers in bio-composite materials for façade cladding applications. Several food-waste streams, including hazelnut and pistachio shells, date seeds, avocado and mango pits, tea leaves, and brewing waste, were processed into fine powders (<0.125 μm) and combined with a furan-based biobased thermoset resin to produce flat composite sheets. The samples were evaluated through mechanical testing (flexural strength, stiffness, and impact resistance), water absorption, freeze–thaw durability, and optical microscopy to assess microstructural characteristics before and after testing. The results reveal substantial performance differences between waste streams. In particular, hazelnut and pistachio shell fillers produced bio-composites suitable for façade cladding, achieving flexural strengths of 62.6 MPa and 53.6 MPa and impact strengths of 3.42 kJ/m² and 1.39 kJ/m², respectively. These findings demonstrate the potential of food-waste-based bio-composites as low-carbon façade cladding materials and highlight future opportunities for optimization of processing, supply chains, and material design. Full article

Spherical caps exploit their intrinsic curvature to achieve efficient stress distribution, delivering exceptional strength-to-weight ratios. This advantage renders them indispensable for aerospace systems, pressurized containers, architectural domes, and structures operating in extreme environments, such as deep-sea or nuclear containment. Their superior load-bearing capacity enables diverse applications, including satellite casings and high-pressure vessels. Meticulous optimization of geometric parameters and material selection ensures robustness in demanding scenarios. Given their significance, this study examines the natural frequency and static response of bio-inspired helicoidally laminated carbon fiber–reinforced polymer matrix composite spherical panels surrounded by Winkler elastic foundation support. Utilizing a 3D elasticity approach and the finite element method (FEM), the governing equations of motion are derived via Hamilton’s Principle. The study compares five helicoidal stacking configurations—recursive, exponential, linear, semicircular, and Fibonacci—with traditional laminate designs, including cross-ply, quasi-isotropic, and unidirectional arrangements. Parametric analyses explore the influence of lamination patterns, number of plies, panel thickness, support rigidity, polar angles, and edge constraints on natural frequencies, static deflections, and stress distributions. The analysis reveals that the quasi-isotropic (QI) laminate configuration yields optimal vibrational performance, attaining the highest fundamental frequency. In contrast, the cross-ply (CP) laminate demonstrates marginally best static performance, exhibiting minimal deflection. The unidirectional (UD) laminate consistently shows the poorest performance across both static and dynamic metrics. These investigations reveal stress transfer mechanisms across layers and elucidate vibration and bending behaviors in laminated spherical shells. Crucially, the results underscore the ability of helicoidal arrangements in augmenting mechanical and structural performance in engineering applications. Full article

Carbon-reinforced epoxy laminated composite (CREC) structures are increasingly utilized in high-speed marine vehicles (HSMVs) due to their high specific strength and stiffness; however, they are frequently subjected to impact loads like slamming and aggressive environmental agents during operation. This study experimentally investigates the Compression After Impact (CAI) behavior of CREC plates with varying lamination sequences under both atmospheric and accelerated aging conditions. The samples were produced using the vacuum-assisted resin infusion method with three specific orientation types: quasi-isotropic, cross-ply, and angle-ply. To simulate the marine environment, specimens were subjected to accelerated aging in a salt fog and cyclic corrosion cabin for periods of 2, 4, and 6 weeks. Before and following the aging process, low-velocity impact tests were conducted at an energy level of 30 J, after which the residual compressive strength was measured by CAI tests. At the end of the aging process, after the sixth week, the performance of plates with different layer configuration characteristics can be summarized as follows: Plates 1 and 2, which are quasi-isotropic, exhibit opposite behavior. Plate 1, with an initial toughness of 23,000 mJ, increases its performance to 27,000 mJ as it ages, while these values are around 27,000 and 17,000 mJ, respectively, for Plate 2. It is thought that the difference in configurations creates this difference, and the presence of the 0° layer under the effect of compression load at the beginning and end of the configuration has a performance-enhancing effect. In Plates 3 and 4, which have a cross-ply configuration, almost the same performance is observed; the performance, which is initially 13,000 mJ, increases to around 23,000 mJ with the effect of aging. Among the options, angle-ply Plates 5 and 6 demonstrate the highest performance with values around 35,000 mJ, along with an undefined aging effect. Scanning Electron Microscopy (SEM) and Energy-Dispersive X-ray Spectroscopy (EDS) analyses confirmed the presence of matrix cracking, fiber breakage, and salt accumulation (Na and Ca compounds) on the aged surfaces. The study concludes that the impact of environmental aging on CRECs is not uniformly negative; while it degrades certain configurations, it can enhance the toughness and energy absorption of brittle, cross-ply structures through matrix plasticization. Full article

Metal-composite joints, leveraging the high specific strength/stiffness and superior fatigue resistance of carbon fiber reinforced polymers (CFRP) alongside metallic materials’ excellent toughness and formability, have become prevalent in aerospace structures. Fastener flexibility serves as a critical parameter governing load distribution prediction and fatigue life assessment, where accurate quantification directly impacts structural reliability. Current approaches face limitations: experimental methods require extended testing cycles, numerical simulations exhibit computational inefficiency, and conventional machine learning (ML) models suffer from “black-box” characteristics that obscure mechanical principle alignment, hindering aerospace implementation. This study proposes an integrated framework combining numerical simulation with explainable ML for fastener flexibility analysis. Initially, finite element modeling (FEM) constructs a dataset encompassing geometric features, material properties, and flexibility values. Subsequently, a random forest (RF) prediction model is developed with five-fold cross-validation and residual analysis ensuring accuracy. SHapley Additive exPlanations (SHAP) methodology then quantifies input features’ marginal contributions to flexibility predictions, with results interpreted in conjunction with theoretical flexibility formulas to elucidate key parameter influence mechanisms. The approach achieves 0.99 R2 accuracy and 0.11 s computation time while resolving explainability challenges, identifying fastener diameter-to-plate thickness ratio as the dominant driver with negligible temperature/preload effects, thereby providing a validated efficient solution for aerospace joint optimization. Full article

In the oil and gas pipeline industry, numerous small-diameter branch pipe fillet welds exist, which are prone to stress concentration because of diverse geometric shapes. The internal welding defects within these welds pose severe hazards to safe production. Specifically, the irregular geometry often leads to internal root defects where the weld metal fails to fully penetrate the joint or fuse with the base material (referred to as incomplete penetration and incomplete fusion). This study developed a GF-CF-GF (CF is carbon fiber, GF is glass fiber) sandwich composite reinforcement structure for pipe fittings with these specific internal defects (main pipe: Φ323.9 × 12.5 mm; branch pipe: Φ76 × 5 mm) through a combination of finite element analysis (FEA) and burst test verification. The inherent correlation between structural factors and pressure-bearing capacity was revealed by analyzing the influence of defect sizes. Based on FEA, the repair layer coverage should be designed to be within 400 mm from the defect along the main pipe wall direction and within 100 mm from the defect along the branch pipe wall direction, with required thicknesses of 5.6 mm for incomplete penetration and 3.2 mm for incomplete fusion. Analysis of the actual burst test pressure curve showed that the elastic-plastic transition interval of the repaired pipes increased by approximately 2 MPa compared to normal undamaged pipes, and their pressure-bearing capacities rose by 1.57 MPa (incomplete penetration) and 1.76 MPa (incomplete fusion). These results demonstrate the feasibility of the proposed reinforcement design, which has potential applications in the safety and integrity of oil and gas transportation. Full article

This study investigates the strengthening mechanisms of a Carbon Fiber-Reinforced Polymer (CFRP) grid and Polymer-modified Cement Mortar (PCM) system for damaged reinforced concrete (RC) beams in flexure. Experimental tests were conducted on five short beams to systematically observe the failure modes, load-carrying capacity, strain development, and deflection evolution. A finite element model was established and validated against the experimental results to analyze the effects of key parameters, including the damage degree, number of grid layers, and grid spacing. Theoretical formulas for calculating the ultimate flexural capacity under different failure modes were also derived. The results demonstrate that strengthening undamaged beams yields a more significant improvement in ultimate and cracking loads than strengthening pre-damaged beams. The composite system effectively suppresses crack propagation by enhancing stiffness, albeit at the expense of reduced ductility. The theoretical predictions show good agreement with the experimental data. Parametric analysis reveals that lightly damaged beams exhibit a higher load-bearing potential, whereas severely damaged beams display more ductile behavior. The increase in load capacity converges when the number of grid layers exceeds three. In contrast, reducing the grid spacing significantly enhances flexural capacity due to improved meso-scale structural effects. Full article

This study systematically investigates the tensile property degradation of Carbon Fabric-Reinforced Cementitious Matrix (CFRCM) composites under anodic polarization, explicitly comparing the effects of three standard-required electrolyte environments (NACE/ISO). CFRCM specimens were polarized for 20 days at current densities of 200 and 400 mA/m² in NaCl, NaOH, and simulated concrete pore solutions. Results reveal that anodic polarization significantly reduces peak tensile strength and post-cracking stiffness, with degradation severity dependent on the electrolyte type (NaCl > NaOH > Pore Solution). Crucially, comparative analysis demonstrates that the strength degradation of carbon fiber bundles embedded in the mortar matrix is more pronounced than that of bare bundles. This work provides essential durability data for CFRCM composites for integrated ICCP-Structural Strengthening systems. Full article

This work presents a microstructure-informed pathway for assigning a material symmetry class to distinguish between tensor components and scalar effective thermal conductivity (ETC) values derived from directional measurements. The framework combines directional thermal measurements with three-dimensional statistical quantification of microstructural features (fibers and voids) to assess whether symmetry assumptions required for tensorial interpretation are justified. Three distinct microstructures of short carbon fiber-reinforced polyetherimide composite were analyzed, with the microstructure statistics altered by the melt extrusion additive manufacturing process parameters. The directional temperature-rise history in the material samples was measured using the Transient Plane Source sensor. The statistics obtained from 3D images of microstructural features were used to assess the material’s anisotropy class to justify the applicability of the transverse isotropic regression method for ETC. One microstructure exhibited characteristics consistent with a statistical transverse isotropy idealization, enabling inference of the ETC tensor; the others did not, and their directional ETC values are treated as test-specific parameters obtained from isotropic model fits. The results also demonstrate that microstructure parameters may strongly influence directional thermal transport. More broadly, this work highlights the need for microstructure-informed justification when interpreting directional measurements as tensor components rather than configuration-dependent scalars, underscoring a critical unresolved gap in the experimental characterization of general anisotropic ETC tensors. Full article

Automated precision drilling is essential for aircraft skin manufacturing, yet current robotic systems face dual challenges: chatter-induced inaccuracies in hole quality and limited access to confined spaces such as air inlets. To overcome these limitations, this paper develops a compact drilling robot for drilling large-curvature skins of aircraft air inlets. Targeting the precision drilling requirements for complex-curvature aircraft air inlets, we present the robot’s overall design scheme, detailing each module’s composition to ensure precision drilling. In-depth analysis of the robot’s large-curvature adaptability precisely calculates the wheel assembly dimensions. To ensure high-precision drilling bit entry into guide mechanisms, a flexible drilling spindle mechanism is designed, with calculated and verified elastic ranges. An integrated intelligent control system is developed, combining vision recognition, real-time pose adjustment, and automated drilling workflow planning. Finally, traversability and drilling capabilities are validated using a simplified air inlet model. Test results confirm successful traversal on R200 mm curvature skins and automated drilling of Carbon Fiber-Reinforced Polymer (CFRP)/7075 aluminum stacks with a diameter of Φ4–Φ6 mm, achieving dimensional errors of less than 0.05 mm and normal direction errors of less than 0.65°. Full article

Fiber Metal Laminates (FML), produced in both monolithic and sandwich configurations with glass-, basalt- and carbon-reinforced composites, were investigated for application in fire-resistant lithium battery boxes. Different resins, including recyclable and bio-based systems, were tested to improve sustainability; cores of recycled PET (RPET, 150 g/dm³, 10 mm) were considered. The study focused on the effect of core introduction on mechanical performance, with the dual goal of reducing weight and achieving stiffness values compliant with automotive OEM standards for lithium battery housings. Results demonstrated that sandwich structures improved stiffness up to 12-fold compared to monolithic laminates, while preserving the corrosion resistance of the outer aluminium layer and the flexural strength of the laminates after 670 h of Neutral Salt Spray (NSS) exposure. Full article