Search Results (264)

With the extensive application of 3D-printed composites across multiple industries, the investigation into their structural reliability under complex loading conditions has become a critical research focus. This study comprehensively employs acoustic emission (AE) monitoring, digital image correlation (DIC) measurement, and micro-computed tomography (Micro-CT) visualization techniques to explore the progressive damage behavior of 3D-printed sandwich-structured composites reinforced with continuous carbon fiber sheets under three-point bending. Mechanical tests show that increasing the fiber content of face sheets from 10% to 20% enhances average bending strength by 56%, while low fiber content compromises stiffness and load-bearing capacity. AE analysis categorizes damage modes into matrix cracking (<50 kHz), debonding/delamination (50–150 kHz), and fiber breakage (>150 kHz) using k-means clustering algorithms. DIC measurement reveals significant structural deformation processes during damage progression. The AE-DIC-Micro-CT combination demonstrates an initial undamaged state, followed by damage initiation and propagation in the subsequent stages. This integrated approach provides an effective method for damage assessment, guiding the design and reliability improvement of 3D-printed composites. Full article

The current study demonstrates the buckling properties of composite laminates reinforced with MWCNT fillers using a novel higher-order shear and normal deformation theory (HSNDT), which considers the effect of thickness in its mathematical formulation. The hybrid HSNDT combines polynomial and hyperbolic functions that ensure the parabolic shear stress profile and zero shear stress boundary condition at the upper and lower surface of the plate, hence removing the need for a shear correction factor. The plate is made up of carbon fiber bounded together with polymer resin matrix reinforced with MWCNT fibers. The mechanical properties are homogenized by a Halpin–Tsai scheme. The MATLAB R2019a code was developed in-house for a finite element model using C⁰ continuity nine-node Lagrangian isoparametric shape functions. The geometric nonlinear and linear stiffness matrices are derived using the principle of virtual work. The solution of the eigenvalue problem enables estimation of the critical buckling loads. A convergence study was carried out and model efficiency was corroborated with the existing literature. The model contains only seven degrees of freedom, which significantly reduces computation time, facilitating the comprehensive parametric studies for the buckling stability of the plate. Full article

Flying wing Unmanned Aerial Vehicles (UAVs) are an interesting flight configuration, considering its benefits over aerodynamic, structural and added stealth aspects. The existing configurations are thoroughly studied from the literature survey and useful observations with respect to design and analysis are obtained. The proposed design method includes distinct calculations of the UAV and modelling using 3D experience. The created innovative models are simulated with the help of computational fluid dynamics techniques in ANSYS Fluent to obtain the aerodynamic parameters such as forces, pressure and velocity. The optimization process continues to add more desired modifications to the model, to finalize the best design of flying wing frame for the chosen application and mission profile. In total, nine models are developed starting with the base model, then leading to the conventional, advanced and nature inspired configurations such as the falcon and dragonfly models, as it has an added advantage of producing high maneuverability and lift. Following this, fluid structure interaction analysis has been performed for the best performing configurations, resulting in the determination of variations in the structural behavior with the imposition of advanced composite materials, namely, boron, Kevlar, glass and carbon fiber-reinforced polymers. In addition to this, a hybrid material is designed by combining two composites that resulted in superior material performance when imposed. Control dynamic study is performed for the maneuvers planned as per mission profile, to ensure stability during flight. All the resulting parameters obtained are compared with one another to choose the best frame of the flying wing body, along with the optimum material to be utilized for future analysis and development. Full article

With the growing need for lightweight, durable, and high-performance structures, additively manufactured (AM) polymer composite structures have captured significant attention in the engineering community. These structures offer considerable advantages in various dynamic engineering sectors including automotive, aviation, and military. Thus, this investigation emphasizes the numerical analysis of the dynamic properties and vibration control of AM polylactic acid (PLA) composite structures reinforced with continuous glass fibers (CGFR-PLA) and carbon fibers (CCFR-PLA), with 0°–0° and 0°–90° layer orientations. The findings of this numerical study are compared and validated against earlier published experimental results. Initially, the numerical models were created using the Abaqus CAE 2024, replicating the actual experimental models. The numerical bending modal frequency of each numerical model is determined, and the 0°–0° oriented models exhibited considerably higher values compared to the corresponding 0°–90° models. Significant differences were noted between the numerical and experimental values in the higher modes, mainly due to existence of voids and misalignment in the actual models that were not considered in numerical models. Following this, a numerical amplitude frequency response (AFR) analysis was conducted to observe vibration amplitude variations as a function of frequency. The AFR numerical results demonstrated consistent trends with the experimental results despite differences between the absolute values of both scenarios. Afterwards, vibration amplitude control analysis was performed under the influence of a macro fiber composite (MFC) actuator. The findings from both numerical and experimental cases revealed that vibration control was noticeably higher in 0°–0° oriented structures compared to 0°–90° structures. Experimental models demonstrated higher vibration control effectiveness than the corresponding numerical models. Although significant differences between the numerical and experimental vibration response values were observed in each composite structure, the numerical results exhibited consistent trends with the experiments. This discrepancy is attributed to the challenge of capturing all boundary conditions of the experimental scenario and incorporating them into the numerical simulation. Full article

The global construction industry faces pressing challenges in enhancing building energy efficiency standards. To address this critical issue, facilitate worldwide green and low-carbon transformation in construction practices and improve the thermal performance of building wall panels to achieve optimal levels, a novel polypropylene fiber-reinforced concrete wall panel has been developed and investigated. A three-dimensional steady-state heat transfer finite element model of the wall panel was established to simulate its thermal performance. Key parameters, including the thickness of the inner and outer concrete layers, insulation layer thickness, connector spacing, and connector arrangement patterns, were analyzed to evaluate the thermal performance of the fiber-reinforced concrete composite sandwich wall panel. The results indicate that the heat transfer coefficients of the G-FCSP and FCSP wall panels were 0.768 W/m² · K and 0.767 W/m² · K, respectively, suggesting that the glass fiber grid had a negligible impact on the thermal performance of the panels. The embedded insulation layer was crucial for enhancing the thermal insulation performance of the wall panel, effectively preventing heat exchange between the two sides. Increasing the thickness of the concrete layers had a very limited effect on reducing the heat transfer coefficient. Reducing the spacing of the connectors improved the load-bearing capacity of the composite wall panel to some extent but had minimal influence on the heat transfer coefficient; to achieve optimal performance by balancing structural load distribution and thermal damage resistance, a connector spacing ranging from 200 mm to 500 mm is recommended. The variation in heat transfer coefficients among the four different connector arrangement patterns demonstrated that reducing the thermal conduction media within the wall panel should be prioritized while ensuring mechanical performance. It is also recommended that the connectors are arranged in a continuous layout. Full article

This study fabricated a C/C-CuNi composite using the hydrothermal co-deposition method and investigated its friction and wear behavior as well as the underlying mechanisms after being subjected to arc discharge ablation. The results indicate that the graphitization degree of the material matrix was significantly enhanced after arc discharge ablation, accompanied by a transformation in the carbon microstructure. Carbon nanotubes and graphene structures were generated in the arc ablation zone. Under low arc discharge density, limited pits and open pores are formed on the material surface, with the generated graphene structures effectively reducing friction. Specifically, CN-5 exhibited a stable friction coefficient, a wear rate of 5.2 mg/km, and partial self-repair capability. In contrast, CN-10, under high arc discharge density, suffered from structural collapse, matrix-fiber debonding, and extensive open pores, leading to increased surface roughness. The combined effects of frictional heat and Joule heating elevated the wear surface temperature, triggering matrix oxidation and a sharp rise in wear rate to 14.7 mg/km. The wear mechanisms of C/C-CuNi composites under continuous arc conditions involve arc erosion wear, oxidative wear, abrasive wear, and adhesive wear. Full article

The use of recycled aggregate concrete (RAC) in construction mitigates environmental pollution by repurposing demolition waste, but its lower compressive strength compared to natural aggregate concrete (NAC) limits broader application. Although carbon fiber reinforced polymer (CFRP) composites and polyvinyl chloride (PVC) tubes have individually been shown to improve concrete strength and ductility, existing studies focus on fully wrapped CFRP jackets on NAC columns and do not systematically explore CFRP–PVC hybrid confinement using strips on RAC. To address this research gap, this study investigates the axial compressive behavior of CFRP–PVC–RAC columns by varying CFRP strip width (from 25 to 75 mm), strip spacing (from 31 to 77.5 mm), and the number of CFRP layers (one to nine) over a central PVC tube. Axial compression tests reveal that specimens with a central CFRP strip width equal to or greater than 75 mm achieve peak loads up to 1331 kN and that, after rupture of the central strip, the remaining strips continue to carry load, producing a more gradual stress–strain decline and enhanced ductility compared to fully wrapped controls (peak load 1219 kN). These results show that CFRP–PVC composites enhance the axial compressive strength and ductility of RAC columns. The confinement mechanism increases the ultimate axial strain and redistributes transverse stresses, delaying brittle failure and improving deformation capacity. When two or more CFRP layers are applied, strip width and spacing affect axial stress by no more than three percent. Increasing layers from one to four raises axial strength by approximately 23 percent, whereas adding layers beyond four yields diminishing returns, with less than a six percent increase. Finally, a multilayer lateral confined pressure formula is derived and validated against thirty-two specimens, exhibiting errors no greater than three percent and accurately predicting effective confinement. These findings offer practical guidance for optimizing strip dimensions and layering in CFRP–PVC reinforcement of RAC columns, achieving material savings without compromising performance. Full article

In recent years, the rapid development of three-dimensional (3D)-printed continuous fiber-reinforced polymer (CFRP) technology has provided novel strategies for customized manufacturing of high-performance composites. This review systematically summarizes research advancements in material systems, processing methods, mechanical performance regulation, and functional applications of this technology. Material-wise, the analysis focuses on the performance characteristics and application scenarios of carbon fibers, glass fibers, and natural fibers, alongside discussions on the processing behaviors of thermoplastic matrices such as polyetheretherketone (PEEK). At the process level, the advantages and limitations of fused deposition modeling (FDM) and photopolymerization techniques are compared, with emphasis on their impact on fiber–matrix interfaces. The review further examines the regulatory mechanisms of fiber orientation, volume fraction, and other parameters on mechanical properties, as well as implementation pathways for functional designs, such as electrical conductivity and self-sensing capabilities. Application case studies in aerospace lightweight structures and automotive energy-absorbing components are comprehensively analyzed. Current challenges are highlighted, and future directions proposed, including artificial intelligence (AI)-driven process optimization and multi-material hybrid manufacturing. This review aims to provide a comprehensive assessment of the current achievements in 3D printing CFRP technology and a forward-looking analysis of existing challenges, offering a systematic reference for accelerating the transformation of 3D printing CFRP technology from laboratory research to industrial-scale implementation. Full article

Aqueous zinc–ion batteries (AZIBs) have garnered considerable attention owing to their inherent safety, cost-effectiveness, and promising electrochemical performance. However, challenges associated with Zn metal anodes, such as dendrite formation, corrosion, and hydrogen evolution, continue to impede their widespread adoption. To overcome these limitations, a flexible and self-standing composite film anode (denoted ZCN) is engineered from a synergistic combination of Zn powder, nanocellulose, and carbon fiber to serve as a high-performance alternative to conventional Zn foil. These three constituents play the roles of enhancing the active area, improving mechanical properties and electrolyte affinity, and establishing a conductive network, respectively. This innovative design effectively mitigates dendrite growth and suppresses parasitic side reactions, thereby significantly improving the cycling stability of ZCN. As a result, this electrode enables the Zn//Zn cell to offer an ultralong lifespan of 2000 h. And the Zn-MnO₂ battery with ZCN anode demonstrates remarkable performance, realizing over 80% capacity retention after 1000 cycles. This study presents a straightforward, scalable, and cost-effective strategy for the development of dendrite-free metal electrodes, paving the way for durable and high-performance AZIBs. Full article

The thermal resistance of carbon fiber–reinforced poly(phenylene sulfide) to harsh oxidative conditions is investigated through thermogravimetric experiments performed in an oxygen atmosphere. While these materials usually show great resistance against thermal decomposition in a nitrogen atmosphere, the experiments in oxygen reveal the total decomposition of both the matrix and the carbon fibers. The Gram–Schmidt signal, obtained by coupling thermogravimetric analysis in standard conditions with Fourier-transform infrared spectroscopy, exhibits multiple events, evidencing that the decomposition proceeds through distinct stages. The first step characterizes the char formation, while the second relates to its oxidative decomposition. A third step, only observed for composites, is interpreted as the signature of the oxidative decomposition of carbon fibers. To mimic the sudden elevation of temperature encountered during a fire, the analyses are performed at rates of up to 500 K min⁻¹. These specific experimental conditions reveal a complex dependence of the thermogravimetric signature on the heating rate. Independent of the atmosphere, nitrogen or oxygen, the characteristic temperature of decomposition follows a bell-shape trend, resulting from the combination of lag effects and thermal-conductivity limitations. Additionally, the increase of the heating rate causes the Gram–Schmidt signal to evolve toward a broad peak with indistinct events. To investigate whether these changes affect the decomposition products, the infrared spectra, continuously recorded to probe the whole decomposition, are compared with those from the database. The char formation is characterized by the production of sulfur dioxide, while carbon dioxide is the main product emitted during both char and fiber oxidative decomposition. Owing to the merging of the decomposition stages, sulfur-dioxide detection is partly supplanted by that of carbon dioxide under fast elevations of temperature. Full article

Additive manufacturing (AM) is one of the most frequently used technologies to produce complex configuration products. Moreover, AM is very well known as a technology which is characterized by a low amount of generated waste and the potential to be called zero-waste technology. As is known, there are seven main groups of technologies described in the ISO/ASTM 52900 standard that allow the use of very different materials from polymers to metals, ceramics, and composites. However, the increased utilization of additively manufactured composites for different applications requires a deeper analysis of production processes and materials’ characteristics. Various AM technologies can be used to produce complex composite structures reinforced with short fibers; however, only material extrusion (MEX)-based technology is used for the production of composites reinforced with continuous fibers (CFs). At this time, five different methods exist to produce CF-reinforced composite structures. This study focuses on co-extrusion with the towpreg method. Because of the complexity and layer-by-layer nature of the process, defects can occur during production, such as poor interlayer adhesion, increased porosity, insufficient impregnation, and others. To eliminate or minimize defects’ influence on mechanical properties and structural integrity of additively manufactured structures, a hypothesis was proposed involving heat treatment. Carbon fiber’s conductive properties can be used to heal the composite structures, by heating them up through the application of electric current. In this research article, an experimental evaluation of conditions for additively manufactured composites with continuous carbon fiber reinforcement for self-healing processes is presented. Mechanical testing was conducted to check the influence of heat treatment on the flexural properties of the composite samples. Full article

The rapid advancement of 3D printing technologies has greatly assisted drone manufacturing, particularly through the use of composite filaments. This paper explores the impact of fiber-reinforced materials, such as carbon-fiber-infused PLA, PETG, and nylon, on the mechanical performance, weight optimization, and functionality of unmanned aerial vehicles (UAVs). The study highlights how additive manufacturing enables the fabrication of lightweight yet structurally robust components, enhancing flight endurance, stability, and payload capacity. Key advancements in high-speed fused filament fabrication (FFF) printing, soluble support materials, and embedded electronics integration are examined, demonstrating their role in producing highly functional UAV parts. Furthermore, the challenges associated with material processing, cost, and scalability are discussed, along with solutions such as advanced extruder designs and hybrid manufacturing approaches that combine 3D printing with CNC machining. By utilizing composite filaments and innovative fabrication techniques, 3D printing continues to redefine drone production, enabling rapid prototyping and on-demand customization. The use of carbon-fiber-infused PLA, PETG, and nylon has demonstrated outstanding improvements in strength-to-weight performance, structural durability, and dimensional stability—key factors for enhancing flight endurance, maneuverability, and payload capacity in UAV applications. These composite materials also support the integration of embedded electronics and functional features, reinforcing their suitability for high-performance drone parts. Looking forward, future research should explore the potential of nanocomposite filaments not as a replacement but as a complementary advancement to existing composites. These materials offer opportunities for further enhancing multifunctionality, such as thermal/electrical conductivity and in situ sensing, which could expand UAV capabilities significantly. Full article

In recent years, there has been a notable concern about the production of cementitious composites due to its high cement consumption and the corresponding carbon footprint. This has led to significant progress within the construction sector in integrating various waste materials as cement alternatives into cementitious composites. In this study, a sustainable high strength fiber reinforced mortar (HS-FRM) was designed with ceramic powder (CP) and metakaolin (MK) materials as partial replacements of the conventional HS-FRM by up to 80%. Magnetized water (MW) was used in the proposed HS-FRM as mixing water and replaced the normal tap water (TW) for producing a more sustainable and higher strength cementitious product. The HS-FRM was cured using four different curing methods, namely, tap water, seawater, air, and sunlight. Fresh, mechanical, durability, and microstructure characteristics were measured and analyzed for the proposed HS-FRM. The results showed that CP can enhance the slump of HS-FRM by up to 50% (achieved at 40% CP), while MK showed the same or less slump (by up to 33%) than that of the conventional HS-FRM. Using up to 80% of either CP or MK in the HS-FRM continuously decreased its 28-day compressive strength by up to 78% or 83%, respectively. The HS-FRM cured in tap water exhibited the highest compressive strength compared to the other curing conditions. The use of MW improved the workability of the HS-FRM by up to 225% and the compressive strength by up to 13%. The microstructure analyses interpreted the reported variation in the HS-FRM compressive strength and showed that using MW in the HS-FRM revealed a dense structure with an adequate bond between the fiber and the matrix with a relatively low number of micro-cracks and pores compared when using TW. The XRD analysis showed higher peaks of Q, C, and L with the presence of MW compared to mixtures made with TW. Full article

Additive manufacturing (AM) has the potential to revolutionize the fabrication of continuous carbon fiber-reinforced polymer composites (CCFRPCs). Among AM techniques, direct ink writing (DIW) with ultraviolet (UV) curable resin shows promise for creating CCFRPCs with high manufacturing speed, high fiber volume fraction, and low energy consumption. However, issues such as incomplete curing and weak interfacial bonding, particularly in dense fiber bundles, limit the mechanical performance. This study addressed these challenges using pre-impregnated systems (PISs), which is a process developed to impregnate dry fiber bundles with partially cured resin before being used for DIW printing, to enhance resin-fiber adhesion and fiber–fiber bonding within fiber bundles. By optimizing resin viscosity and curing conditions in the PIS process, samples treated by PIS achieved improved mechanical properties. Tensile and bending tests revealed significant performance gains over non-PIS treated samples, with tensile stiffness increasing by at least 39% and bending stiffness by 45% in 3K fiber bundles. Tensile samples with thicker fiber bundles (6K and 12K) exhibited similar improvements. On the other hand, while all samples exhibit enhanced mechanical properties under bending deformation, the improvement of flexural stiffness and strength with thicker fiber bundles is shown to be less significant than those with 3K fiber bundles. Overall, composites made with PIS-treated fibers can enhance mechanical performance compared with those made with non-PIS-treated fibers, offering the scaling capability of printing thicker fiber bundles to reduce processing time while maintaining improved properties. It emphasizes the importance of refining the pre-processing strategies of large continuous fiber bundles in the AM process to achieve optimal mechanical properties. Full article

Carbon staple fiber composites are materials reinforced with discrete-length carbon fibers processed using traditional textile technologies, offering moderate mechanical properties and flexibility in manufacturing. These composites can be produced from recycled carbon staple fibers, aligned into yarn and tape-like structures, providing a more sustainable alternative while balancing performance, cost-effectiveness, and environmental impact. Aligning staple fibers into tape-like structures enables similar applications to those of continuous-fiber-based products, while allowing control over fiber orientation distribution, fiber volume fraction, and length distribution, which are all critical factors influencing both mechanical and thermo-mechanical properties. This study focuses on the experimental characterization and numerical investigation of Coefficients of Thermal Expansion (CTEs) in aligned carbon staple fiber composites. The effects of fiber orientation and volume fraction on coefficients of thermal expansion under different fiber alignment parameters are analyzed, revealing distinct thermal expansion behavior compared to typical aligned unidirectional continuous carbon fiber composite laminates. Unlike continuous unidirectional laminates, which typically exhibit transversely isotropic behavior without tensile–shear coupling, staple fiber composites demonstrate different in-plane axial, transverse, and out-of-plane CTE characteristics. To explain these deviations, a modeling approach is introduced, incorporating detailed experimental information on fiber distributions and microstructural features rather than averaged fiber orientation values. This involves a multi-scale analysis based on a laminate analogy through which all composite thermo-elastic properties can be predicted, accounting for variations in fiber orientations, volume fractions, and tape thicknesses. It is shown that while the local variation of fiber volume fraction has a small effect on the homogenized value of the coefficients of thermal expansion, fiber misalignment, tape thickness, and asymmetry in fiber orientation distribution will significantly affect the measurements of CTEs. For the case of carbon staple fiber composites, the asymmetry in fiber orientation distribution significantly influences the measurements of axial CTE. Fiber orientation asymmetry causes tensile–shear coupling under mechanical and thermal loading, leading to an unbalanced laminate with in-plane shear–tensile deformation. This coupling disrupts uniform displacement, complicating strain measurements and the determination of composite properties. Full article