Search Results (245)

This study systematically investigates the high-velocity impact response and energy absorption characteristics of carbon fiber-reinforced plastic (CFRP)—aluminum foam (AlF) hybrid composite structures, aiming to address the growing demand for lightweight yet high-performance energy-absorbing materials in aerospace and protective engineering applications. Particular emphasis is placed on elucidating the influence of key geometric and material parameters, including the aspect ratio of the columns and the relative density of the AlF core. Experimental characterization was first performed using a split Hopkinson pressure bar (SHPB) apparatus to evaluate the dynamic compressive behavior of AlF specimens with four different relative densities (i.e., 0.163, 0.245, 0.374, and 0.437). A finite element (FE) model was then developed and rigorously validated against the experimental data, demonstrating excellent agreement in terms of deformation modes and force–displacement responses. Extensive parametric studies based on the validated FE framework revealed that the proposed CFRP-AlF composite structure achieves a balance between specific energy absorption (SEA) and peak crushing force, showing a significant improvement over conventional CFRP or AlF. The confinement effect of CFRP enables AlF to undergo progressive collapse along designated orientations, thereby endowing the CFRP-AlF composite structure with superior impact resistance. These findings provide critical insight for the design of next-generation lightweight protective structures subjected to extreme dynamic loading conditions. Full article

Carbon fiber-reinforced plastics (CFRPs) offer excellent in-plane mechanical performance, but their relatively low interlaminar fracture toughness makes them vulnerable to delamination, particularly around intralaminar discontinuities such as resin-rich regions or fiber gaps. This study investigates the effectiveness of polyamide (PA) mesh inserts in improving interlaminar toughness and suppressing delamination in CFRP laminates with such features. Two PA mesh configurations were evaluated: a fully embedded continuous layer and a 20 mm cut mesh strip placed between continuous and discontinuous plies near critical regions. Fracture toughness tests showed that PA mesh insertion improved interlaminar toughness approximately 2.4-fold compared to neat CFRP, primarily due to a mechanical interlocking mechanism that disrupts crack propagation and enhances energy dissipation. Uniaxial tensile tests with digital image correlation revealed that while initial matrix cracking occurred at similar stress levels, the stress at which complete delamination occurred was approximately 60% higher in specimens with a 20 mm mesh and up to 92% higher in specimens with fully embedded mesh. The fully embedded mesh provided consistent delamination resistance across the laminate, while the 20 mm insert localized strain redistribution and preserved global mechanical performance. These findings demonstrate that PA mesh is an effective interleaving material for enhancing damage tolerance in CFRP laminates with internal discontinuities. Full article

The thermal stability of carbon fiber-reinforced plastic (CFRP) materials is constrained by the low thermal conductivity of its polymer matrix, resulting in inefficient heat dissipation, local overheating, and accelerated degradation during thermal loads. To overcome these limitations, composite materials can be modified with buckypapers—thin, densely interconnected layers of carbon nanotubes (CNTs). In this study, sixteen 8552/IM7 prepreg plies were processed with up to nine buckypapers and strategically placed at various positions. The resulting nanocomposites were evaluated for manufacturability, material properties, and thermal resistance. The findings reveal that prepreg plies provide only limited matrix material for buckypaper infiltration. Nonetheless, up to five buckypapers, corresponding to 8 wt.% CNTs, can be incorporated into the material without inducing matrix depletion defects. This integration significantly enhances the material’s thermal properties while maintaining its mechanical integrity. The nanotubes embedded in the matrix achieve an effective thermal conductivity of up to 7 W/(m·K) based on theoretical modeling. As a result, under one-sided thermal irradiation at 50 kW/m², thermo-induced damage and strength loss can be delayed by up to 20%. Therefore, thermal resistance is primarily determined by the nanotube concentration, whereas the arrangement of the buckypapers affects the material quality. Since this innovative approach enables the targeted integration of high particle fractions, it offers substantial potential for improving the safety and reliability of CFRP under thermal stress. Full article

In recent times, fiber reinforced polymer composite materials have become more popular due to their remarkable features such as high specific strength, high stiffness and durability. Particularly, Carbon Fiber Reinforced Polymer (CFRP) composites are one of the most prominent materials used in the field of transportation and building engineering, replacing conventional materials due to their attractive properties as mentioned. In this work, a CFRP laminate is fabricated with carbon fiber mats and epoxy by a hand layup technique. Alumina (Al₂O₃) micro particles are used as a filler material, mixed with epoxy at different weight fractions of 0% to 4% during the fabrication of CFRP laminates. The important objective of the study is to investigate the influence of alumina micro particles on the mechanical performance of the laminates through characterization for various physical and mechanical properties. It is revealed from the results of study that the mass density of the laminates steadily increased with the quantity of alumina micro particles added and subsequently, the porosity of the laminates is reduced significantly. The SEM micrograph confirmed the constituents of the laminate and uniform distribution of Al₂O₃ micro particles with no significant agglomeration. The hardness of the CFRP laminates increased significantly for about 60% with an increase in weight % of Al₂O₃ from 0% to 4%, whereas the water gain % gradually drops from 0 to 2%, after which a substantial rise is observed for 3 to 4%. The improved interlocking due to the addition of filler material reduced the voids in the interfaces and thereby resist the absorption of water and in turn reduced the plasticity of the resin too. Tensile, flexural and inter-laminar shear strengths of the CFRP laminate were improved appreciably with the addition of alumina particles through extended grain boundary and enhanced interfacial bonding between the fibers, epoxy and alumina particles, except at 1 and 3 wt.% of Al₂O₃, which may be due to the pooling of alumina particles within the matrix. Inclusion of hard alumina particles resulted in a significant drop in impact strength due to appreciable reduction in softness of the core region of the laminates. Full article

Prefabricated unidirectional carbon fiber reinforced polymer (CFRP) composite strips are extensively used as a means of infrastructure rehabilitation through adhesive bonding to the external surface of structural concrete elements. Most data to date are from laboratory tests ranging from a few months to 1–2 years providing an insufficient dataset for prediction of long-term durability. This investigation focuses on the assessment of the response of three different prefabricated CFRP systems exposed to water, seawater, and alkaline solutions for 5 years of immersion in deionized water conducted at three temperatures of 23, 37.8 and 60 °C, all well below the glass transition temperature levels. Overall response is characterized through tensile and short beam shear (SBS) testing at periodic intervals. It is noted that while the three systems are similar, with the dominant mechanisms of deterioration being related to matrix plasticization followed by fiber–matrix debonding with levels of matrix and interface deterioration being accelerated at elevated temperatures, their baseline characteristics and distributions are different emphasizing the need for greater standardization. While tensile modulus does not degrade appreciably over the 5-year period of exposure with final levels of deterioration being between 7.3 and 11.9%, both tensile strength and SBS strength degrade substantially with increasing levels based on temperature and time of immersion. Levels of tensile strength retention can be as low as 61.8–66.6% when immersed in deionized water at 60 °C, those for SBS strength can be 38.4–48.7% at the same immersion condition for the three FRP systems. Differences due to solution type are wider in the short-term and start approaching asymptotic levels within FRP systems at longer periods of exposure. The very high levels of deterioration in SBS strength indicate the breakdown of the materials at the fiber–matrix bond and interfacial levels. It is shown that the level of deterioration exceeds that presumed through design thresholds set by specific codes/standards and that new safety factors are warranted in addition to expanding the set of characteristics studied to include SBS or similar interface-level tests. Alkali solutions are also shown to have the highest deteriorative effects with deionized water having the least. Simple equations are developed to enable extrapolation of test data to predict long term durability and to develop design thresholds based on expectations of service life with an environmental factor of between 0.56 and 0.69 for a 50-year expected service life. 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

This review explores the evolving landscape of sustainable textile manufacturing, with a focus on rubber-based materials for various industrial applications. The textile and rubber industries are shifting towards eco-friendly practices, driven by environmental concerns and the need to reduce carbon footprints. The integration of sustainable textiles in rubber-based products, such as tires, conveyor belts, and defense products, is becoming increasingly prominent. This review discusses the adoption of natural fibers like flax, jute, and hemp, which offer biodegradability and improved mechanical properties. Additionally, it highlights sustainable elastomer sources, including natural rubber from Hevea brasiliensis and alternative plants like Guayule and Russian dandelion, as well as bio-based synthetic rubbers derived from terpenes and biomass. The review also covers sustainable additives, such as silica fillers, nanoclay, and bio-based plasticizers, which enhance performance while reducing environmental impact. Textile–rubber composites offer a cost-effective alternative to traditional fiber-reinforced polymers when high flexibility and impact resistance are needed. Rubber matrices enhance fatigue life under cyclic loading, and sustainable textiles like jute can reduce environmental impact. The manufacturing process involves rubber preparation, composite assembly, consolidation/curing, and post-processing, with precise control over temperature and pressure during curing being critical. These composites are versatile and robust, finding applications in tires, conveyor belts, insulation, and more. The review also highlights the advantages of textile–rubber composites, innovative recycling and upcycling initiatives, addressing current challenges and outlining future perspectives for achieving a circular economy in the textile and rubber sectors. Full article

This research utilized recycled acetate fibers from discarded cigarette butts (CBs) as reinforcing materials, reducing solid waste and enhancing the properties of bitumen. The surface properties of the fibers significantly impacted the binder characteristics. The treatment of CB fibers with anhydrous ethanol was employed to remove the plasticizer glycerol triacetate (GTA), enabling the better homogeneity of the fibers in the binder. Thermogravimetric analysis (TGA) and scanning electron microscopy (SEM) were used to assess the effectiveness of the fiber treatment. A dynamic shear rheometer (DSR) was used to explore the properties of bitumen with varying CB contents (0%, 0.25%, 0.75%, and 1.25% by weight). A whole life cycle analysis further confirmed the eco-efficiency of CB binders. The results show that the pretreatment effectively removed GTA, leading to a more homogeneous dispersion of fibers in the binder. Adding CBs can significantly improve bitumen properties, but this effect does not increase with higher dosages; when the CB content exceeded 1.25%, a reduction in fatigue resistance was observed. Among the tested dosages, the optimal amount was 0.75%, which improved the high-temperature performance of the binder by 2.7 times, the medium-temperature fatigue life by 1.78 times, and the low-temperature performance by 1.08 times. In terms of ecological benefits, the addition of CB fibers to bitumen pavement reduced carbon emissions by two-thirds compared to traditional bitumen pavement, resulting in a significant decrease in carbon emissions. This study provides valuable insights into the construction of sustainable transportation infrastructure. Full article

The recycling of waste materials that are usually expensive to dispose of, such as carbon fiber reinforced plastic (CFRP) dust and ferrous dust or sludge, can open up interesting economic prospects and free up landfill space. The agglomeration process is used to combine these two types of waste and produce an aggregate that can be used in shaft furnaces. The carbon contained in the CFRP dust serves as a potential reducing agent in metallurgical processes. The report shows the technical parameters of the wet agglomeration with subsequent sintering for the production of the pellets and provides evidence of the material recycling of the carbon fiber waste. A comparison with primary pellets shows the suitability. Full article

In the present research, laser circle welding (LCW) was proposed to join dual-phase steel (DP980) and carbon fiber-reinforced plastic (CFRP). The welding appearance, cross-section of the welded joint and fracture surfaces were subjected to multi-scale characterizations. Joining strength was evaluated by the single-lap shear test. Moreover, a numerical model was established based on the in-house finite element (FE) code JWRIAN-Hybrid to reproduce the thermal process of LCW. The results showed that successful bonding was achieved with a laser power higher than 300 W. The largest joining strength increased to about 1353.2 N (12.2 MPa) with 450 W laser power and then decreased under higher heat input. While the welded joint always presented brittle fracture, the joining zone could be divided into a squeezed zone (SZ), molten zone (MZ) and decomposition zone (DZ). The morphology of CFRP and chemical bonding information were distinct in each subregion. The chemical reaction between the O-C=O bond on the CFRP surface and the -OH bond on the DP980 sheet provided the joining force between dissimilar materials. Additionally, the developed FE model was effective in predicting the interfacial maximum temperature distribution of LCW. The influence of laser power on the joining strength of LCW joints was dualistic in character. The joining strength variation reflected the competitive result between joining zone expansion and local bonding quality change. Full article

Burrs generated during the drilling of carbon fiber-reinforced plastics (CFRPs) would seriously reduce the service life of the components, potentially leading to assembly errors and part rejection. To solve this issue, this paper proposed a finite element (FE) model with multiscale modeling to investigate the formation and distribution of burrs at various processing conditions. The FE model comprised the microscopic fiber and resin phases to predict the formation process of burrs, while part of the CFRP layers was defined to be macroscopic equivalent homogeneous material (EHM) to improve the computational efficiency. A progressive damage constitutive model was proposed to simulate the different failure modes and damage propagation of fibers. The impact of strain rate on the mechanical properties of the resin and CFRP layers was considered during the formulation of their constitutive models. With this numerical model, the formation process of the burrs and the drilling thrust force were accurately predicted compared to the experimental measurements. Then, the burr distributions were analyzed, and the influences of the drill bit structures and drilling parameters on burrs were assessed. It was concluded that the burrs were easily generated in the zones with 0° to 90° fiber cutting angles at the drilling exit. The sawtooth structure could exert an upward cutting effect on burrs during the downward feed of the tool; thus, it is helpful for the inhibition of burrs. More burrs were produced with higher feed rates and reduced spindle speeds. Full article

A numerical simulation investigating the frequency dependence of fatigue damage progression in carbon fiber-reinforced plastics (CFRPs) is conducted in this study. The initiation and propagation of transverse cracks under varying fatigue test frequencies are successfully simulated, consistent with experiments, using an enhanced degradable Hashin failure model that was originally developed by the authors in 2022. The results obtained from the numerical simulation in the present study, which employs adjusted numerical values for the purpose of damage acceleration, indicate that the number of cycles required for the formation of three transverse cracks was 174 cycles at 0.1 Hz, 209 cycles at 1 Hz, and 165 cycles at 10 Hz. Based on these results, it is demonstrated that under high-frequency cyclic loading, internal heat generation caused by dissipated energy from mechanical deformation, attributed to the viscoelastic and/or plastic behavior of the material, exceeds thermal dissipation to the environment, leading to an increase in specimen temperature. Consequently, damage progression accelerates under high-frequency fatigue. In contrast, under low-frequency fatigue, viscoelastic dissipation becomes more pronounced, reducing the number of cycles required to reach a similar damage state. The rate of damage accumulation initially increases with test frequency but subsequently decreases. This observation underscores the importance of incorporating these findings into discussions on the fatigue damage of real structural components. Full article

Continuous fibers with outstanding mechanical performance due to the continuous enhancement effect, show wide application in aerospace, automobile, and construction. There has been great success in developing continuous synthetic fiber-reinforced composites, such as carbon fibers or glass fibers; however, most of which are nonrenewable, have a high processing cost, and energy consumption. Bio-sourced materials with high reinforced effects are attractive alternatives to achieve a low-carbon footprint. In this study, continuous bamboo fiber-reinforced polyethylene (CBF/PE) composites were prepared via a facile two-step method featuring alkali treatment followed by 3D printing. Alkali treatment as a key processing step increases surface area and surface wetting, which promote the formation of mechanical riveting among bamboo fibers and matrix. The obtained treated CBF (T-CBF) also shows improved mechanical properties, which enables a superior reinforcement effect. 3D printing, as a fast and local heating method, could melt the outer layer PE tube and impregnate molten plastics into fibers under pressure and heating. The resulting T-CBF/PE composite fibers can achieve a tensile strength of up to 15.6 MPa, while the matrix PE itself has a tensile strength of around 7.7 MPa. Additionally, the fracture morphology of printed bulks from composite fibers shows the alkali-treated fibers–PE interface is denser and could transfer more load. The printed bulks using T-CBF/PE shows increased tensile strength and Young’s modulus, with 77%- and 1.76-times improvement compared to pure PE. Finally, the effect of printing paraments on mechanical properties were analyzed. Therefore, this research presents a potential avenue for fabricating continuous natural fiber-reinforced composites. Full article

Park golf, introduced to Korea in 2000, has become a popular leisure activity, especially among older people. However, sudden shock between the ball and carbon fiber-reinforced plastic (CFRP) face can increase the risk of injuries, highlighting the need for enhanced damping material. However, restitution and damping are critical properties of golf clubs and often exhibit a conflicting relationship; thus, a method is needed to address this challenge. Therefore, this study aimed to develop a CFRP with an enhanced restitution and damping ratio by incorporating carbon nanotubes and graphene oxide nanofillers into the existing CFRP face material. A drop test apparatus was set up to measure the coefficient of restitution, and the damping properties were evaluated using a pencil lead-breaking test. CNTs exhibited high rebound properties due to their stiffness and hardness. In contrast, GO provided a modest increase in rebound while demonstrating a superior damping ratio, attributed to its layered structure and high internal friction. Based on these results, the optimal nanofiller content was determined as GO 0.025 wt%, showing a minor improvement in rebound performance, a 1033% improvement in vibration damping, and an 84% improvement in acoustic damping. Notably, this finding implies the importance of nanomaterial shape and its interaction with the composite matrix. A double-masked user test with a prototype confirmed enhanced comfort and reduced vibration feedback. The low-vibration components developed in this study are expected to be applicable in future research for controlling the damping ratio under impact or vibrations, such as UAM and helicopters. Full article

Carbon-fiber-reinforced plastic (CFRP) is a popular material possessing great properties, such as strength, lightness, and resistance to corrosion and the environment. Important steps in the production of various parts made of CFRP are surface structuring, milling, drilling and cutting processes. Here, we propose to use ultrashort pulse lasers to achieve the high-quality, low-heat-affected-zone ablation of CFRP. We investigated the ablation efficiency dependence on the processing parameters, such as the pulse duration, pulse energy and pulse overlap. We showed that good-quality results could be achieved using just low-/mid-average-power femtosecond laser equipment. We also discuss further cutting process optimization possibilities using ultrashort pulse lasers and show the possibility of HAZ-free CFRP cutting by femtosecond laser ablation. Full article