Search Results (2,938)

Hybrid composite laminates combining pseudo-woven meso-architectured composite (MAC) and unidirectional (UD) sub-laminates manufactured via automated fiber (AFP) placement are attractive as they combine the increased toughness of MAC and higher stiffness of UD while also reducing the manufacturing time. MACs are manufactured via a modified AFP process involving tow skips to create a woven-like architecture using unidirectional tows and introduce shallow crimp angles and complex fiber angle distributions in the architecture. Previous studies on hybrid MAC laminates have shown increased impact damage resistance/tolerance under high- and low-velocity impacts. This work presents an experimental study on the open-hole tension (OHT) and open-hole compression (OHC) response of T800-SC-24k carbon/epoxy laminates of nominal thickness 4.55 mm manufactured via AFP manufacturing. Two hybrid laminate configurations consisting of a UD core and pseudo-woven MAC sub-laminates on the outer surfaces are compared against a traditional UD quasi-isotropic control laminate. One of the hybrid laminate configurations has a plain-woven-like architecture while the other has a complex 3D woven type architecture. The hybrid laminates exhibited a marginal 7% increase in OHT strength and up to a 16% reduction in normal loading direction strains around the hole relative to the control. All three configurations showed comparable OHC strengths. Despite the complex meso-architecture of the MAC sub-laminates, failure in both OHT and OHC is found to be governed primarily by the UD core, which dominates load-carrying capability and failure mechanisms. The results demonstrate that the hybrid laminates maintained or improved in-plane OHT/OHC performance while previously demonstrating better damage resistance and tolerance under impact. Full article

The water-lubricated piston–cylinder pair is a critical tribological component in hydraulic systems, yet its performance under boundary lubrication is often limited by high friction and severe wear. Conventional epoxy coatings provide only modest improvements. In this study, graphene-modified epoxy composite coatings were developed and applied to piston substrates, then characterized via scanning electron microscopy, white light interferometry, and nanoindentation. Tribological performance was evaluated using a reciprocating tribometer under simulated pump conditions of 16 MPa and 1500 r/min. Compared to the pure epoxy coating, the graphene-modified coating reduced the friction coefficient by 33.9% and the wear rate by 77.2%, while the graphene oxide-modified coating reduced them by 16.1% and 64.5%, respectively. These results demonstrate that graphene-modified epoxy composite coatings offer an effective surface engineering solution for enhancing the durability and efficiency of water-lubricated systems, with promising potential for water hydraulic applications. Full article

Epoxy-glass-mica composite materials are widely used as electrical insulating materials in high-voltage rotating machinery due to their layered structure and excellent dielectric properties. Taking the F-class epoxy glass with a small amount of rubber powder mica tape commonly used as the main insulation of wind turbine stator coils as the research object, 7-day, 14-day, 21-day, and 28-day low-temperature treatment tests were conducted at −50 °C. The surface morphology and chemical structure changes of the materials were characterized by SEM and FTIR, and the influence laws of low-temperature treatment on the electrical properties of the mica tape insulation materials were systematically studied. The experimental results show that the low-temperature environment will induce microcracks and interface delamination and other structural damages, but no obvious change in the chemical structure of the mica tape was observed. With the extension of the low-temperature treatment time, the electrical properties of the mica tape show a deteriorating trend, and after 28 days of low-temperature treatment, the breakdown field strength of the F-class mica tape decreased by approximately 18.5%, and the volume conductivity overall increased by about two orders of magnitude. This indicates that the microcrack defects induced by low-temperature will lead to an enhanced electrical-thermal coupling effect in the insulation structure, thereby accelerating the degradation process of the insulation material. This reveals the degradation mechanism of wind turbine stator main insulation from “structural damage” to “performance degradation” and then to “insulation aging” under low-temperature conditions, providing a theoretical basis for the design and reliability assessment of insulation systems in wind turbine generators in cold regions. Full article

Soft magnetic composite materials have a low total loss and high magnetic conductivity and are highly desirable for high-frequency motors, semiconductors, and 5G communication technologies. However, these composites often contain a high-volume fraction of soft magnetic metallic powders and are difficult to process into complex shapes. Herein, iron-based amorphous powders were surface-modified with silane coupling agents (DTMS and KH570) and applied in 3D direct ink writing (DIW). The modified powders exhibit improved compatibility and dispersion in epoxy resin. The optimized 92.3 wt% FeSiB@3.35 wt% KH570/EP slurry shows favorable rheological properties and a dense interfacial microstructure. The printed composite achieves the best magnetic performance (M_s: 137.02 ± 1.2 emu/g, H_c: 6.63 ± 0.2 Oe) and stable permeability up to 1 GHz. The surface modification enhanced slurry fluidity, preventing nozzle blockage and increasing powder loading. Various shaped magnetic cores were successfully fabricated with excellent magnetic properties and printing quality. Our work paves a new way for realizing the high processibility of soft magnetic composites, which lays a foundation for a technique for the wide applications of these materials in various electronic devices. Full article

This work presents a comparative study of micro- and nano-scale fillers in liquid composite molding processes, focusing on how particle size and morphology affect resin rheology, flow behavior, and filler filtration within fiber preforms. Glass microspheres and organo-modified montmorillonite were dispersed in epoxy resin and injected through glass-mat preforms at different fiber volume fractions (ranging from 0.27 to 0.47). Our study integrates rheological characterization, in situ flow-front tracking, unsaturated permeability analysis, thermogravimetric quantification of retained particles, and microstructural observations by SEM. Despite their smaller loading, nanoclay suspensions showed a markedly higher viscosity increase than microsphere systems, yet their permeability remained nearly unchanged. In contrast, microsphere-filled resins exhibited strong filtration at the flow inlet, density-driven settling near the lower tool face, and significant permeability loss. The results demonstrate that nano-fillers, although more viscous, maintain homogeneous distribution and flow continuity, whereas micro-fillers promote cake formation and local compaction. This controlled side-by-side comparison clarifies how filler size and shape govern filtration mechanisms in liquid composite molding (LCM), providing design guidelines for processing filled resin systems without compromising part quality. Full article

The crack resistance of unidirectional fiberglass-reinforced plastics based on an epoxy matrix modified with polysulfone (PSU) and furfuryl glycidyl ether (FGE) was investigated. The combined addition of PSU/FGE modifiers to the epoxy matrix increases the crack resistance of glass-fiber-reinforced plastics (GFRPs). The effect of increasing the crack resistance of GFRPs varies depending on the modifier ratio. The greatest increase in crack resistance is achieved with a modifier ratio of 1/0.5. For this ratio, the value of $G_{IR}^{CM}$ is 1.18 kJ/m² (for unmodified GFRP, $G_{IR}^{CM}$ = 0.72 kJ/m²). With an increase in the FGE concentration in the polysulfone-modified epoxy matrix, the crack resistance of GFRP decreases to a level of ~0.8 kJ/m². The change in the crack resistance of GFRP is associated with the structure of the epoxy matrix containing different PSU/FGE ratios. A study of the fracture surfaces of GFRPs showed that the greatest increase in the crack resistance of composites is achieved with the formation of extended phases enriched with polysulfone in the epoxy matrix. The size of the dispersed phase is about 3 μm. A correlation has been established between the crack resistance of hybrid matrices and GFRPs. With an increase in the matrix crack resistance by 3.1 times (from 0.37 to 1.15 kJ/m²), the fracture toughness value of GFRP increased by 1.6 times (from 0.72 to 1.18 kJ/m²). Full article

In this work, we demonstrate that both carbon nanotubes (CNT) and graphene nanosheets (G) were successfully modified by π-stacking interactions with a pyrene derivative (PY), yielding the functionalized nanofillers CNT-PY and G-PY, which were subsequently dispersed within an aeronautical epoxy matrix. This functionalization is highly effective in preserving the remarkable electronic properties of carbon nanotubes and graphene nanosheets. At the same time, the non-covalent functionalization reduces the resin viscosity, enabling a more effective dispersion of the nanofillers. This results in improved rheological behavior and an overall enhancement of the structural performance of the nanocomposites compared to the resin containing unfunctionalized carbon nanofillers (CNT and G). Additional improvements are also observed in electrical properties, self-healing efficiency, and thermal stability. In particular, the samples containing functionalized carbon nanotubes (TBD + 1%CNT-PY) and functionalized graphene nanosheets (TBD + 1%G-PY) exhibit higher conductivities—0.391 S/m and 0.1 S/m, respectively—than the samples loaded with unfunctionalized carbon nanotubes (TBD + 1%CNT) and unfunctionalized graphene nanosheets (TBD + 1%G), which show conductivity values of 0.292 S/m and 4.82 × 10⁻³ S/m, respectively. The functionalized graphene nanosheets (G-PY) display significantly greater thermal stability, with degradation temperatures reaching 670 °C, compared to 310 °C for unfunctionalized ones (G). The functionalized carbon nanotubes (CNT-PY) show a 10% weight loss at 520 °C due to the degradation of the pyrene groups. Significant improvements in the final properties can be achieved when carbon-based nanofillers are homogeneously dispersed in the matrix and the external load is efficiently transferred through strong filler–polymer interfacial interactions, leading to composites with superior characteristics suitable for advanced applications. Tunneling Atomic Force Microscopy (TUNA) highlights the morphological features of the two types of carbon nanofillers, their dispersion within the polymer matrix and the effect of the functionalization on the electrical pathways and conductivity of the samples at both the micro- and nanometer-scale. The measured electrical conductivities are consistent with the electric currents detected at the micro/nanoscale. Full article

Accurate quantification of phosphogypsum (PG) filler in epoxy composites is essential for quality control and performance optimization. Conventional separation by muffle furnace calcination suffers from slow epoxy decomposition and risks thermal degradation of CaSO₄, leading to inaccurate PG quantification. This study introduces a microwave-assisted separation method that leverages molecular vibration heating to achieve faster heating rates and more uniform temperature distribution, enabling complete epoxy removal while minimizing CaSO₄ decomposition. Comprehensive characterization (X-ray diffraction, XRD; Fourier transform infrared spectroscopy, FT-IR; scanning electron microscopy-energy dispersive spectroscopy, SEM-EDS) confirms the structural integrity of the isolated PG filler. Among five quantification methods evaluated, inductively coupled plasma optical emission spectrometry (ICP-OES) based on sulfur content provides the highest accuracy (spike recovery: 91–99.8%, relative standard deviation, RSD ≤ 4.2%), while gravimetry suffices for single-filler systems. This work establishes a reliable analytical framework for PG characterization in epoxy composites, supporting quality control and resource valorization. Full article

In liquid composite moulding processes, the curing behaviour of thermoset matrices plays a decisive role in determining manufacturing quality and cycle time. Premature demoulding may lead to insufficiently cured components, whereas excessively long curing times reduce production efficiency. Reliable monitoring and modelling of the curing process are therefore essential for process optimisation. In this study, the cure kinetics of a fast-curing epoxy resin system are modelled using the Grindling kinetic model, which accounts for diffusion-controlled reaction behaviour and vitrification effects. Model parameters are identified using both dynamic and isothermal differential scanning calorimetry (DSC) measurements. In addition, the glass transition temperature is described as a function of the degree of cure using the DiBenedetto relationship. To demonstrate the applicability of the model for process monitoring, an experimental mould equipped with temperature sensors was developed to simulate real-time estimation of the degree of cure during isothermal processing. The predicted degree of cure is validated by post-process DSC analysis of the manufactured samples. Initial comparisons reveal systematic deviations caused by temperature measurement uncertainties. After implementing a temperature correction based on experimentally determined sensor deviations, the predicted degree of cure shows significantly improved agreement with DSC measurements. The results demonstrate that combining kinetic modelling with temperature monitoring enables reliable real-time estimation of the curing state for fast-curing epoxy systems. The study also highlights the critical importance of accurate temperature measurement for curing monitoring and provides insights into the practical implementation of sensor-based monitoring strategies in liquid composite moulding processes. Full article

In this work, the debonding behavior under quasi-static Mode I fracture loading of adhesive joints made on two types of composite materials with the same epoxy matrix and unidirectional carbon or glass fiber reinforcement was analyzed. Standard DCB tests were used to quantify the influence of adhesive type and substrate surface preparation on interlaminar fracture toughness. For the fabrication of the joints under study, three commercial structural adhesives from different manufacturers were selected, two epoxy-based and one acrylic-based. Substrate surface preparation was carried out using three different procedures: manual abrasion, sanding with P220 Al₂O₃ sandpaper, grit blasting with Al₂O₃, and peel ply PA80 polyamide fabric. The experimental results revealed the same trend for both epoxy-based adhesives: sanding provided the best results, regardless of the substrate used. Surface preparation by grit blasting proved highly sensitive to the applied parameters, generally yielding poorer results than manual sanding. Surface preparation using PA80 peel ply fabric may be a viable option. However, its main drawback is that it must be incorporated during composite manufacturing. The results demonstrate that fracture performance is governed by the interaction between adhesive chemistry and surface morphology rather than by surface roughness alone. Full article

Conventional adhesives for plywood are mostly derived from petroleum-based materials and commonly suffer from formaldehyde emission, posing threats to the environment and human health. In this study, a renewable resource, Xanthoceras sorbifolium Bunge oil, was used as the raw material. A high-performance bio-based adhesive was successfully prepared by synthesizing Xanthoceras sorbifolium Bunge oil dimethacrylate (MXOEA) as a reactive diluent, blending it with acrylated epoxy Xanthoceras sorbifolium Bunge oil (AEXO), and introducing 2-isocyanatoethyl methacrylate (IEM) to enhance crosslinking. The effects of the MXOEA/AEXO ratio and the IEM addition level on the properties of the adhesive and the resulting plywood were systematically investigated. The results showed that when the mass ratio of AEXO to MXOEA was 3:7, and the IEM content was 10%, the adhesive exhibited the best bonding performance: the resulting plywood achieved a modulus of rupture of 68.85 MPa, a modulus of elasticity of 8086 MPa, and dry and wet bonding strengths of 3.21 MPa and 2.32 MPa, respectively. Mechanistic analysis indicated that the introduction of IEM moderately reduced the viscosity of the adhesive system. Meanwhile, the isocyanate groups in IEM reacted with the hydroxyl groups on the wood surface, forming a chemical crosslinking structure at the adhesive-wood interface, which is considered one of the reasons for the improved mechanical properties of the plywood. This study provides a formaldehyde-free, high-performance bio-based adhesive derived from Xanthoceras sorbifolium Bunge oil for the field of wood-based composites. Full article

This study investigates the residual stresses developed during the curing process of polymer fiber-reinforced composites and their influence on fracture behavior, particularly the initiation and propagation of interlaminar cracks. The main objective is to quantify how different curing histories, including incomplete cure, alter the spatial distribution of residual stresses and, in turn, affect the mode-I fracture response of carbon-fiber/epoxy laminates. A transient thermal–structural finite element framework incorporating an autocatalytic cure kinetics model was used to simulate the curing process and predict residual stress development in a unidirectional carbon-fiber/epoxy laminate with an edge crack, considering thermal, chemical, and geometric effects. The cure model was calibrated using isothermal differential scanning calorimetry data to determine the degree of cure under different thermal conditions. The key novelty of this work is the integration of a validated cure-kinetics-based curing simulation with fracture analysis, enabling direct correlation of thermal history and degree of cure with spatially varying residual stresses at the crack front and their effect on fracture toughness. Numerical load–displacement predictions were compared with double cantilever beam experimental results and showed good agreement for the curing profiles examined. The results demonstrate that residual stresses generated by different cure cycles, including hold conditions and incomplete curing, significantly influence fracture toughness. In particular, the incomplete-cure profile produced an approximately 40% reduction in toughness compared with profiles that achieved complete cure, highlighting the importance of cure history in determining final structural performance. Full article

This study investigates the ballistic performance and energy dissipation mechanisms of epoxy composites reinforced with raffia fabric at fiber volume fractions of 10%, 20%, and 30% under 9 mm full metal jacket projectile impact. Ballistics tests were conducted to determine impact and residual velocities, absorbed energy, absorption efficiency, equivalent ballistic limit, and momentum reduction. All tests were performed at similar impact velocities (≈433 m/s), corresponding to an incident energy of approximately 750 J. The results revealed a clear inverse relationship between raffia content and energy absorption capability. The ER10 composite exhibited the highest performance, with an absorbed energy of 176.7 ± 9.7 J, absorption efficiency of 23.5 ± 0.9%, and momentum reduction of 0.1253 ± 0.0053. Increasing the fiber fraction to 20% (ER20) and 30% (ER30) led to progressive reductions in absorbed energy to 119.7 ± 2.7 J and 77.7 ± 9.0 J, with efficiencies of 15.95 ± 0.26% and 10.30 ± 1.12%, respectively. The residual velocity increased from 379.3 ± 2.5 m/s (ER10) to 397.0 ± 2.1 m/s (ER20) and 411.1 ± 1.6 m/s (ER30). One-way ANOVA detected statistically significant differences in absorbed energy and absorption efficiency among the different fiber volume fractions (p < 0.001). The results demonstrate a trade-off between stiffness and toughness and indicate that raffia-reinforced composites can play complementary roles in sustainable multilayered armor systems. Full article

To clarify the effect of surface characteristics on the interfacial properties of T1100-grade carbon fiber (CF)/bismaleimide (BMI) composites, three CFs (F1, F2, and F3) with different surface treatments and sizing agents were studied. Surface physicochemical properties and sizing–resin reaction behavior were characterized; nano-infrared spectroscopy was innovatively used to quantify interfacial structure. The correlation among surface features, interfacial structure, and mechanical properties was established. All dry-jet wet-spun T1100 CFs show smooth surfaces with similar roughness, and mechanical interlocking contributes little to interfacial adhesion. F3 possesses the highest active carbon, oxygen content, and epoxy value. Its sizing agent exhibits strong reactivity with BMI, forming a ~200 nm thick interface and the highest interfacial shear strength (IFSS) of 95.9 MPa. Constructing a “thick and strong” interface promotes shear failure from brittle to tough, significantly enhancing 90° tensile and interlaminar shear strength (ILSS). This work provides guidance for interface design and engineering applications of T1100/BMI composites in aerospace primary load-bearing structures. Full article

High-cycle fatigue (HCF) behavior of multi-scale hybrid composites remains a critical area of investigation for advanced applications in aerospace and automotive industries. This study aims to experimentally investigate and optimize the HCF performance of carbon–Kevlar/epoxy hybrid composites through synergistic incorporation of nano-silica (nSiO₂) and nano-graphene (nGr). Laminates were fabricated using a hand lay-up process followed by press molding, with a [2 carbon fiber/4 Kevlar fiber/2 carbon fiber] stacking sequence. Sixteen material configurations were investigated based on a Taguchi design of experiment (DOE), with two input parameters (nanoparticle percentages) at four different levels each. Following tensile screening tests, three optimal formulations were selected for fatigue evaluation alongside a non-reinforced baseline. Axial fatigue tests were conducted under load-controlled conditions with a stress ratio of R = 0.01 at a constant frequency of 5 Hz. Stress levels were set at 65%, 70%, and 75% of the ultimate tensile strength (UTS), which ranged from 211 MPa for the baseline composite to 390 MPa for the optimal hybrid formulation (1.2 wt.% nSiO₂ and 0.75 wt.% nGr). Scanning electron microscopy (SEM) analysis of fracture surfaces was performed to correlate microstructural features with fatigue performance. The results demonstrate a remarkable synergistic effect. The optimal hybrid nanocomposite exhibited superior fatigue life, sustaining significantly higher maximum stress (253 MPa vs. 137 MPa at 65% UTS) and achieving a life increase of several-fold compared to the non-modified baseline. SEM observations revealed that this enhancement stems from complementary microstructural mechanisms: nSiO₂ particles are uniformly dispersed without agglomeration, providing matrix toughening through crack deflection, while nGr sheets enhance interfacial adhesion, as evidenced by complete matrix coverage on fiber surfaces. The optimal formulation uniquely displays both mechanisms operating simultaneously, creating a true multi-scale reinforcement architecture. In contrast, sub-optimal formulations showed nanoparticle agglomerations that acted as stress concentrators under cyclic loading, explaining their intermediate fatigue performance despite high static strength. Full article