Search Results (156)

This study explores the application of low-power vibrothermography (LVT) for detecting barely visible impact damage (BVID) in carbon fibre-reinforced polymer (CFRP) laminates. Composite specimens with varying impact energies (2.5–20 J) were excited using a single piezoelectric transducer with a nominal centre frequency of 28 kHz, operated at a fixed excitation frequency of 28 kHz. Thermal data were captured using an infrared camera. To enhance defect visibility and suppress background noise, the raw thermal sequences were processed using principal component analysis (PCA) and robust principal component analysis (RPCA). In LVT, RPCA and PCA provided comparable signal-to-noise ratios (SNR), with no consistent advantage for either method across all cases. In contrast, for pulsed thermography (PT) data, RPCA consistently resulted in higher SNR values, except for one sample. The LVT results were further validated by comparison with PT and phased array ultrasonic testing (PAUT) data to confirm the location and shape of detected damage. These findings demonstrate that LVT, when combined with PCA or RPCA, offers a reliable method for identifying BVID and can support safer, more efficient structural health monitoring of composite materials. Full article

The increasing demand for lightweight, high-performance materials in marine and offshore engineering has driven the development of hybrid solutions combining metals and composites. This study investigates the stress corrosion cracking (SCC) and tribocorrosion behaviour of a novel hybrid wire consisting of a superaustenitic stainless steel (6Mo) outer shell and a carbon fibre-reinforced polymer (CFRP) core. Microstructural analysis, residual stress measurement, and corrosion testing were performed to assess the integrity of the welded structure under harsh conditions. The results revealed that residual stresses and interdendritic segregation in the weld zone significantly contribute to SCC susceptibility, while the 6Mo steel showed improved corrosion resistance over 316L under tribocorrosion conditions but was more sensitive to the sliding frequency. These findings provide critical insights into the degradation mechanisms of metal composite hybrid wires and support the future design of corrosion-resistant components for offshore and structural applications. Full article

In drilling Carbon-Fibre-Reinforced Polymers (CFRP)/Al stacks, adaptive drilling facilitates the optimisation of cutting parameters for each constituent stack layer and tool wear, thus enhancing cutting efficiency and borehole quality. This study proposed a knot–Temporal Pyramid Pooling (TPP) model aimed at monitoring both process incidences and tool wear in the drilling of hybrid stacks, which subsequently informs the machine tool to adjust cutting parameters or, if necessary, replaces the tool. TPP is introduced to remove the restriction of input dimensions, allowing for the acceptance of inputs with arbitrary shapes. On the other hand, a knot structure has been proposed to incorporate the classification of process incidences into the tool wear analysis, thereby enhancing prediction accuracy. The proposed model achieves a process incidence identification accuracy of 99.19% and a Mean Absolute Error (MAE) of 10 μm in tool wear prediction, demonstrating robust performance across a wide range of sampling conditions. This achievement facilitates decision-making and optimisation relating to cutting parameters and tool replacement in the context of adaptive drilling of aerospace materials. Full article

This study explores advanced process monitoring for one-shot drilling of aeronautical stacks made of aluminium 2024 and carbon fibre-reinforced polymer (CFRP) laminates using a 4.8 mm diameter drilling tool and unsupervised machine learning techniques. An experimental campaign is conducted to collect thrust force and torque signals at a 10 kHz sampling rate during the drilling process. These signals are employed for real-time process monitoring, focusing on material change detection and anomaly identification, where anomalies are defined as holes that fail to meet predefined quality criteria. An innovative approach based on unsupervised learning is proposed to enable automatic material change identification, signal segmentation, feature extraction, and hole quality assessment. Specifically, a semi-supervised approach based on a Gaussian Mixture Model (GMM) and 1D Convolutional AutoEncoder (1D-CAE) is employed to detect deviations from normal drilling conditions. The proposed method is benchmarked against state-of-the-art supervised techniques, including logistic regression (LR) and Support Vector Machines (SVMs). Results show that these traditional models struggle with class imbalance, leading to overfitting and limited generalisation, as reflected by the F1 scores of 0.78 and 0.75 for LR and SVM, respectively. In contrast, the proposed semi-supervised approach improves anomaly detection, achieving an F1 score of 0.87 by more effectively identifying poor-quality holes. This study demonstrates the potential of deep learning-based semi-supervised methods for intelligent process monitoring, enabling adaptive control in the drilling process of hybrid stacks and detecting anomalous holes. While the proposed approach effectively handles small and imbalanced datasets, further research into the application of generative AI could enhance performance, aiming for F1 scores above 0.90, thereby supporting adaptation in real industrial environments with high performance. Full article

Forming hybrid structures into complex shapes is key to address lightweighting of automotive parts. Recently, an innovative joining technique between aluminium and Carbon Fibre-Reinforced Polymer (CFRP) based on mechanical interlocking through sheet punching has been developed. However, scaling up the solution requires the assessment of challenges, such as multi-material forming and joint integrity, after forming operations. Therefore, this work proves the feasibility of forming aluminium–CFRP prepreg panels into complex omega-shaped profiles following a conventional cold-stamping process. Forming without defects was possible even in specimens featuring mechanical joints generated through punching. The effect of the CFRP position (in the inner or the outer side of the formed profile), the number of mechanical joints, the addition of a Glass Fibre-Reinforced Polymer (GFRP) intermediate layer to prevent galvanic corrosion and adequate lubrication on necking, cracking, springback behaviour and the final geometry after curing were studied. Compression tests were performed to assess the mechanical response of the hybrid profile, and the results showed that the addition of CFRP in the aluminium omega profile changed the buckling behaviour from global bending to axial folding, increasing the maximum compression load. Additionally, the presence of mechanical interlocking joints further improved the mechanical performance and led to a more controlled failure due to buckling localization in the geometric discontinuity. Full article

To achieve the sustainability goals set for the European aviation sector, hydrogen-powered solutions are currently being investigated. Storage solutions are of particular interest, with liquid hydrogen tanks posing numerous challenges with regard to the structural integrity of materials at cryogenic temperatures, as well as safety issues because of the high flammability of hydrogen. In this context and in the scope of the Horizon 2020 Clean Aviation Joint Undertaking (CAJU) project H2ELIOS, the gas permeability behavior of prepreg tape carbon fibre reinforced polymer (CFRP) material was studied. Investigations were performed after thermal shock to 20 K (liquid hydrogen immersion) as well as after a uniaxial stress application at 77 K to identify the shift from Fickian behavior after diverse aging conditions. Helium gas permeation was tested at room temperature (RT), and its representativeness to hydrogen permeation in a range of temperatures was considered in the study. The material’s permeation behavior was compared to ideal Fickian diffusion as a means of identifying related permeation barrier function degradation. Finally, it was possible to identify Fickian, near-Fickian, and non-Fickian behaviors and correlate them with the material’s preconditioning. Full article

The growing use of fibre-reinforced polymers (FRPs) is driving a demand for the development of sustainable end-of-life strategies. Solvolysis, a chemical recycling method using solvents to decompose the polymer matrix, has emerged as a promising approach for reclaiming both fibres and organic compounds from FRP waste. This work provides a comprehensive overview of solvolysis techniques by discussing the environmental benefits and economic opportunities of this technology, summarising the process conditions, and evaluating the characteristics of the recovered products. The economic viability of solvolysis lies in recovering high-value components; predominantly carbon fibres from CFRPs and organic products from GFRPs, which are suitable for reuse or as a feedstock for new composites. Solvolysis can operate under low temperature and pressure (LTP) or high temperature and pressure (HTP) conditions. The choice of solvent, catalyst, reaction time, and temperature is crucial to achieving high resin decomposition while preserving fibre properties. To achieve an economically viable and environmentally beneficial process, it will be essential to optimise these parameters. A key challenge is maintaining the strength and surface properties of the recovered fibres, as degradation in their performance can limit their suitability for high-performance applications. The implication of this is that, without careful consideration of the recycling process, FRPs cannot be fully circular. They will be continuously downgraded into low-value applications and ultimately incinerated or landfilled. This review further explores the diversity of organic products obtained, which can range from monomers to oligomers to complex mixtures. Efficient separation and upgrading techniques, such as distillation and liquid–liquid extraction, are essential to maximise the value of the recovered organics. These additional processing steps are likely to result in greater financial and resource costs within a commercial recycling system. This review concludes with a summary of commercial solvent-based recycling ventures and an outlook on future research directions, which includes the need to develop processes capable of recovering high-value, long carbon fibres. Successful development of such a process would represent a step-change in the value proposition of a carbon fibre recycling industry. Full article

A novel hot-melt cyclic olefin-based adhesive was designed as a transparent, non-tacky film of amorphous thermoplastic with a unique polymer micro-structure. The aim of the present paper is to assess the mechanical properties of the 0.1 mm thick COP hot-melt adhesive film through adhesive characterizations tests. The glass transition temperature was determined using dynamic mechanical analysis (DMA). For mechanical characterization, bulk and thick adherend shear specimens were manufactured and tested at a quasi-static rate, where at least three specimens were used to calculate the average and standard deviation values. Tensile tests revealed the effects of molecular chain drawing and reorientation before the onset of strain hardening. Thick adherend shear specimens were used to retrieve shear properties. Fracture behaviour was assessed with the double cantilever beam (DCB) test and end-notched flexure (ENF) test, for characterization under modes I and II, respectively. To study the in-joint behaviour, single lap joints (SLJs) of aluminium and carbon fibre-reinforced polymer (CFRP) were manufactured and tested under different temperatures. Results showed a progressive interfacial failure following adhesive plasticization, allowing deformation prior to failure at 8 MPa. An adhesive failure mode was confirmed through scanning electron microscopy (SEM) analysis of aluminium SLJ. The adhesive exhibits tensile properties comparable to existing adhesives, while demonstrating enhanced lap shear strength and a distinctive failure mechanism. These characteristics suggest potential advantages in applications involving heat and pressure across automotive, electronics and structural bonding sectors. Full article

Carbon fibre-reinforced polymers (CFRPs) are a lightweight alternative solution for various applications due to their mechanical and structural properties. However, debonding at the fibre–matrix interface is an important failure mechanism in composite materials. Proposed solutions include using nano-scale reinforcements to strengthen and toughen structural composites. This study covers a comprehensive approach for evaluating occupational hazards during the sizing of 6k carbon fibres using multi-walled functionalized carbon nanotubes (MWCNTs) and few-layer graphene (FLG) at a pilot scale. Material hazard and exposure banding showed elevated risks of exposure to nanomaterials during the sizing process, while a ‘what-if’ process hazard analysis allowed for the evaluation of hazard control options against the hypothetical process failure scenarios of human error and utilities malfunctioning. On-site measurements of airborne particles highlighted that using MWCNTs or FLG as a sizing agent had negligible effects on the overall exposure potential, and higher micro-size particle concentrations were observed at the beginning of the process, while particle size distribution showcased high concentrations of particles below 50 nm. This analysis provides a thorough investigation of the risks and potential exposure to airborne hazardous substances during CF sizing while providing insights for the effective implementation of a safe-by-design strategy for designing targeted hazard control systems. Full article

The bending stiffness of beams represents a pivotal parameter influencing both the dimensions of the elements during their design and their subsequent utilisation. It is evident that excessive deflections can cause discomfort to users and contribute to further structural degradation. The objective of this study was to enhance the bending stiffness of timber beams by bonding a composite sheet to their external surfaces. A carbon sheet exhibiting an ultra-high modulus of elasticity and low elongation at rupture was employed. Two variables of analysis can be distinguished including whether the reinforcement was applied or not and the number of reinforcement layers. The beams, with nominal dimensions of 80 × 80 × 1600 mm, were subjected to a four-point bending test in order to ascertain their mechanical properties. In total, 15 beams were tested (5 unreinforced and 10 reinforced). The reinforcement had no appreciable impact on the increase in flexural load capacity, with the maximum average increase recorded at 9%. Nevertheless, an increase in stiffness of 34% was observed. Additionally, significant increases were observed in ductility up to 248%. However, the ductile behaviour of the beam occurred after the rupture of the reinforcement. In all instances, the failure was attributed to the fracturing of the wooden components or the UHM CFRP (ultra-high-modulus-carbon-fibre-reinforced polymer) sheet. The numerical analysis proved to be a valuable tool for predicting the stiffness of the wood–composite system, with a relatively low error margin of a few percentage points. The modified approach, based on the equivalent cross-section method, permits the determination of a bilinear load deflection relationship for reinforced beams. The aforementioned curve is indicative of the actual behaviour. Given the propensity for the sudden rupture of reinforcement, the described method of reinforcement is recommended for beams subjected to lower levels of stress. Full article

The recycling of Carbon Fibre-Reinforced Polymers (CFRPs) is becoming increasingly crucial due to the growing demand for sustainability in high-performance industries such as automotive and aerospace. This study investigates the impact of two chemical recycling techniques, chemically assisted solvolysis and plasma-enhanced solvolysis, on the morphology and properties of carbon fibres (CFs) recovered from end-of-life automotive parts. In addition, the effects of fibre sizing are explored to enhance the performance of the recycled carbon fibres (rCFs). The surface morphology of the fibres was characterised using Scanning Electron Microscopy (SEM), and their structural integrity was assessed through Thermogravimetric Analysis (TGA) and Raman spectroscopy. An automatic analysis method based on optical microscopy images was also developed to quantify filament loss during the recycling process. Mechanical testing of single fibres and yarns showed that although rCFs from both recycling methods exhibited a ~20% reduction in tensile strength compared to reference fibres, the application of sizing significantly mitigated these effects (~10% reduction). X-ray Photoelectron Spectroscopy (XPS) further confirmed the introduction of functional oxygen-containing groups on the fibre surface, which improved fibre-matrix adhesion. Overall, the results demonstrate that plasma-enhanced solvolysis was more effective at fully decomposing the resin, while the subsequent application of sizing enhanced the mechanical performance of rCFs, restoring their properties closer to those of virgin fibres. Full article

Macroscopic structures consisting of two or more materials are called composites. The decreasing reserves of the world’s oil reserve and the environmental pollution of existing energy and production resources made the use of recycling methods inevitable. There are mechanical, thermal, and chemical recycling methods for the recycling of thermosets among composite materials. The recycling of thermoset composite materials economically saves resources and energy in the production of reinforcement and matrix materials. Due to the superior properties such as hardness, strength, lightness, corrosion resistance, design width, and the flexibility of epoxy/vinylester/polyester fibre formation composite materials combined with thermoset resin at the macro level, environmentally friendly sustainable development is happening with the increasing use of composite materials in many fields such as the maritime sector, space technology, wind energy, the manufacturing of medical devices, robot technology, the chemical industry, electrical electronic technology, the construction and building sector, the automotive sector, the defence industry, the aviation sector, the food and agriculture sector, and sports equipment manufacturing. Bonded joint studies in composite materials have generally been investigated at the level of a single composite material and single joint. The uncertainty of the long-term effects of different composite materials and environmental factors in single-lap bonded joints is an important obstacle in applications. The aim of this study is to investigate the effects of single-lap bonded GFRP (glass fibre-reinforced polymer) and CFRP (carbon fibre-reinforced polymer) specimens on the material at the end of seawater exposure. In this study, 0/90 orientation twill weave seven-ply GFRP and eight-ply CFRP composite materials were used in dry conditions (without seawater soaking) and the hand lay-up method. Seawater was taken from the Aegean Sea, İzmir province (Selçuk/Pamucak), in September at 23.5 °C. This seawater was kept in different containers in seawater for 1 month (30 days), 2 months (60 days), and 3 months (90 days) separately for GFRP and CFRP composite samples. They were cut according to ASTM D5868-01 for single-lap joint connections. Moisture retention percentages and axial impact tests were performed. Three-point bending tests were then performed according to ASTM D790. Damage to the material was examined with a ZEISS GEMINESEM 560 scanning electron microscope (SEM). The SEM was used to observe the interface properties and microstructure of the fracture surfaces of the composite samples by scanning images with a focused electron beam. Damage analysis imaging was performed on CFRP and GFRP specimens after sputtering with a gold compound. Moisture retention rates (%), axial impact tests, and three-point bending test specimens were kept in seawater with a seawater salinity of 3.3–3.7% and a seawater temperature of 23.5 °C for 1, 2, and 3 months. Moisture retention rates (%) are 0.66%, 3.43%, and 4.16% for GFRP single-lap bonded joints in a dry environment and joints kept for 1, 2, and 3 months, respectively. In CFRP single-lap bonded joints, it is 0.57%, 0.86%, and 0.87%, respectively. As a result of axial impact tests, under a 30 J impact energy level, the fracture toughness of GFRP single-lap bonded joints kept in a dry environment and seawater for 1, 2, and 3 months are 4.6%, 9.1%, 14.7%, and 11.23%, respectively. At the 30 J impact energy level, the fracture toughness values of CFRP single-lap bonded joints in a dry environment and in seawater for 1, 2, and 3 months were 4.2%, 5.3%, 6.4%, and 6.1%, respectively. As a result of three-point bending tests, GFRP single-lap joints showed a 5.94%, 8.90%, and 12.98% decrease in Young’s modulus compared to dry joints kept in seawater for 1, 2, and 3 months, respectively. CFRP single-lap joints showed that Young’s modulus decreased by 1.28%, 3.39%, and 3.74% compared to dry joints kept in seawater for 1, 2, and 3 months, respectively. Comparing the GFRP and CFRP specimens formed by a single-lap bonded connection, the moisture retention percentages of GFRP specimens and the amount of energy absorbed in axial impact tests increased with the soaking time in seawater, while Young’s modulus was less in three-point bending tests, indicating that CFRP specimens have better mechanical properties. Full article

The construction sector is one of the largest creators and distributors of wealth, contributing to economic growth worldwide. However, this economic growth comes together with very high environmental impacts. Thus, rehabilitation solutions that can adapt the current building stock to today’s structural requirements are needed, increasing structural safety, while avoiding the production of demolition waste and the extraction of virgin raw materials, hence lowering the construction sector’s environmental impacts. Such rehabilitation solutions need to be environmentally and economically sound so that stakeholders can make informed decisions based on their needs and priorities. This paper presents a case study of an existing reinforced concrete beam, whose flexural resistance is increased using four alternative strengthening solutions: concrete jacketing, without and with increasing the cross-section size, and plate bonding, using either carbon fibre-reinforced polymer (CFRP) strips or steel plates. These solutions are studied via an environmental and economic cradle-to-gate life cycle assessment (LCA), resulting in a comprehensive comparison of their environmental and economic impacts, followed by a multicriteria and sensitivity analysis and eco-cost approach to determine the optimal solution. According to the criteria considered in the study, when environmental impacts are more valued, the concrete jacketing solution presents the best results and, when cost is dominant in the decision, the bonding of CFRP strips becomes the optimal solution. Full article

Several challenges arise during edge trimming of carbon fibre-reinforced polymer (CFRP) composites, such as the formation of machining-induced burrs and delamination. In a recent development, appropriate-quality geometric features in CFRPs can be machined using special cutting tools and optimised machining parameters. However, these suitable technologies quickly become inappropriate due to the accelerated tool wear. Therefore, the main aim of our research was to find a novel solution for maintaining the machined edge quality even if the tool condition changed significantly. We developed a novel mechanical edge-trimming technology inspired by wobble milling, i.e., the composite plate compression is governed by the proper tool tilting. The effectiveness of the novel technology was tested through mechanical machining experiments and compared with that of conventional edge-trimming technology. Furthermore, the influences of the tool tilting angle and the permanent chamfer size on the burr characteristics were also investigated. A one-fluted solid carbide end mill with a helix angle of 0° was applied for the experiments. The machined edges were examined trough stereomicroscopy and scanning electron microscopy. The images were evaluated through digital image processing. Our results show that multi-axis edge-trimming technology produces less extensive machining-induced burrs than conventional edge trimming by an average of 50%. Furthermore, we found that the tool tilting angle has a significant impact on burr size, while permanent chamfer does not influence it. These findings suggest that multi-axis edge trimming offers a strong alternative to conventional methods, especially when using end-of-life cutting tools, and highlight the importance of selecting the optimal tool tilting angle to minimize machining-induced burrs. Full article

The strengthening, rehabilitation and repair of wooden beams and beams made of wood-based materials are still important scientific and technical issues. This is reflected, among other things, in the number of scientific articles appearing and the involvement of research centres around the world. This is also related to society’s growing belief in the importance of ecological and sustainable development. This article presents an overview of the latest work in this field and the results of our own research on strengthening solid wooden beams with carbon-fibre-reinforced polymer (CFRP) sheets. The tests were carried out on full-size solid beams with nominal dimensions of 70 × 170 × 3300 mm. A 0.333 mm thick CFRP sheet was used for reinforcement. The research analysed various reinforcement configurations and different reinforcement ratios. For the most effective solution, a 46% increase in load capacity, 35% stiffness and 249% ductility were achieved with a reinforcement ratio of 1.7%. Generally, the higher the reinforcement ratio and coverage of the surface of the wood, the higher the strengthening effectiveness. The brittle fracture of wood in the tensile zone for unreinforced beams and the ductile crushing of wood in the compressive zone for reinforced beams were obtained. The most important achievement of this work is the description of the static work of beams in previously unanalysed configurations of strengthening and the confirmation of their effectiveness. The described solutions should extend the life of existing wooden buildings and structures and increase the competitiveness of wooden-based structures. The results indicate that, from the point of view of optimizing the cost of reinforcement, it is crucial to develop cheaper ways of combining wood and composite than to verify different types of fibres. Full article