Search Results (31)

In this study, the development of a novel machine mount utilizing an advanced polymer composite and porous materials is presented. Initially, a preliminary evaluation of the proposed materials was conducted, focusing on their static mechanical properties and their dynamic properties, and assessed through loading–unloading cycles and Dynamic Mechanical Thermal Analysis (DMTA). All tests were performed at the coupon scale, with specimens manufactured via Fused Filament Fabrication (FFF). Subsequently, a conceptual design incorporating the proposed materials was developed, and functional prototypes were fabricated using multi-material additive manufacturing techniques. The structural integrity of the prototypes was evaluated by analyzing their oscillatory response and damping behavior under laboratory-scale conditions, with transmissibility metrics extracted to quantify performance. The results indicate that all three prototypes exhibit adequate damping for machine mounting applications, ranging between 5% and 20%, with the porous variant demonstrating the highest damping performance (20.9%). In terms of load-bearing capacity, the porous configuration withstood loads up to 10 kN, while the standard TPU variant sustained up to 20 kN. The carbon-fiber-reinforced configuration exhibited the highest mechanical performance, tolerating loads up to 50 kN without significant structural failure. Full article

Three-dimensional braided carbon-fiber-reinforced polymer (CFRP) composites are promising for lightweight aircraft propeller blades. Aircraft composite structures may approach temperatures of 80–90 °C under the combined effects of solar radiation, infrared heating, and ground reflection. Yet the thermo-mechanical failure mechanisms of low-braiding-angle architecture remain insufficiently understood. This study comparatively investigates the tensile behavior and damage evolution of low-angle four-directional (3D4A-20°) and five-directional (3D5A-20°) braided CFRP composites under axial tension at both room temperature and 90 °C. A multi-scale approach integrating in situ X-ray computed tomography, digital image correlation, digital volume correlation, and scanning electron microscopy was used to characterize strain localization, internal cracking, and fracture morphology. At room temperature, 3D5A-20° shows higher stiffness and strength than 3D4A-20° because additional axial yarns improve load-transfer and three-dimensional constraint. At 90 °C, matrix softening and interfacial degradation accelerate crack initiation, strain localization, and damage propagation in both architectures. Nevertheless, 3D5A-20° maintains more stable and progressive damage evolution, whereas 3D4A-20° exhibits earlier crack coalescence and greater mechanical degradation. Overall, elevated temperature accelerates damage evolution through matrix softening and interfacial degradation, whereas braided architecture determines load transfer and crack connectivity. These findings provide guidance for the design of low-angle braided composites for thermally exposed aircraft propeller blades. 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

In response to thermal failure risks in ultra-high voltage (UHV) bushing online monitoring devices and maintenance equipment—caused by high heat generation of electronic components and the intrinsically low thermal conductivity of conventional resin encapsulation materials—this study proposes a novel modification strategy based on flash Joule heating (FJH). Distinct from conventional interface modification methods, the proposed approach enables cross-scale, in situ microsoldering between multi-walled carbon nanotubes (MWCNTs) and carbon fibers (CFs), constructing a multiscale reinforcement network with integrated thermal transport and mechanical load transfer pathways. The transient ultra-high-temperature thermal shock generated by FJH not only effectively removes inert impurities on CF surfaces but also drives carbon structural reconstruction, enabling graphitic-level welding of MWCNTs onto the fiber surface. This micro-welded architecture fundamentally differs from traditional filler dispersion or interface coating strategies, which often suffer from the trade-off between interfacial thermal transport and mechanical bonding. By contrast, the FJH-induced carbon–carbon bonded nodes form a continuous conductive and load-bearing network at the micro–nano scale. Characterizations using scanning electron microscopy (SEM), Raman spectroscopy, and X-ray photoelectron spectroscopy (XPS) confirm successful in situ welding of MWCNTs onto CF surfaces. Meanwhile, FJH treatment effectively removes oxygen-containing functional groups and surface impurities. Analysis of carbon bonding evolution indicates that the welding efficiency reaches its maximum at 90 V. Macroscopic performance tests demonstrate that, compared with epoxy resin, the thermal conductivity of the multiscale reinforced system increases by approximately 168%, while the mechanical strength improves by 62.72%. This study provides new theoretical insights and technical pathways for the development of next-generation polymer composite materials with both high thermal conductivity and high mechanical strength. Full article

Carbon nanotubes (MWCNTs) were synthesized in situ on para-aramid fabrics (gCPO) via a low-temperature (450 °C) chemical vapor deposition (CVD) process to enhance interfacial pull-out, frictional, and fracture toughness characteristics. FESEM analysis confirmed CNT coverage on fiber surfaces, while FTIR, Raman, and XRD results indicated limited structural modification without significant polymer degradation. The CNT-functionalized fabrics exhibited a 66.19% increase in maximum pull-out force, 55.32% improvement in interlacement rupture strength, and a three-fold rise in intra-yarn shear resistance compared with control fabrics (KPO). The static and kinetic friction coefficients increased by 26.67% and 16.67%, respectively, due to CNT-induced surface roughness, enhancing inter-fiber load transfer and reducing slippage. Single-yarn pull-out tests revealed notable gains in energy dissipation and fracture toughness (up to 1769 J/m²), whereas multi-yarn pull-out performance decreased due to excessive friction surpassing filament strength. The study demonstrates that low-temperature MWCNT growth enables effective interfacial reinforcement of soft para-aramid fabrics, establishing a novel framework for meso-scale mechanical screening of flexible nano-ballistic composites. Full article

Magnesium phosphate cement (MPC) has gained attention in specialized construction applications due to its rapid setting and high early strength, though its inherent brittleness limits structural performance. This study developed an innovative toughening strategy through synergistic reinforcement using hybrid fibers and carbon fiber-reinforced polymer (CFRP) fabric capable of multi-scale crack control. The experimental program systematically evaluated the hybrid fiber system, dosage, and CFRP positioning effects through mechanical testing of 7-day cured specimens. The results indicated that 3.5% fiber dosage optimized flexural–compressive balance (45% flexural gain with <20% compressive reduction), while CFRP integration at 19 mm displacement enhanced flexural capacity via multi-scale reinforcement. Fracture analysis revealed that the combined system increases post-cracking strength by 60% through coordinated crack bridging at micro (fiber) and macro (CFRP) scales. These findings elucidated the mechanisms by which fiber–CFRP interaction mitigates MPC’s brittleness through hierarchical crack control while maintaining its rapid hardening advantages. The study established quantitative design guidelines, showing the fiber composition of CF/WSF/CPS15 = 1/1/1 with 19 mm CFRP placement achieves optimal toughness–flexural balance (f_f/f_c > 0.38). The developed composite system reduced brittleness through effective crack suppression across scales, confirming its capability to transform fracture behavior from brittle to quasi-ductile. This work advances MPC’s engineering applicability by resolving its mechanical limitations through rationally designed composite systems, with particular relevance to rapid repair scenarios requiring both early strength and damage tolerance, expanding its potential in specialized construction where conventional cement proves inadequate. Full article

Concrete structures increasingly face dynamic loading conditions, such as seismic events, vehicular traffic, and environmental vibrations, necessitating enhanced energy dissipation capabilities. The damping ratio, a critical parameter quantifying a material’s ability to dissipate vibrational energy, is typically low in conventional concrete, prompting extensive research into strategies for improvement. This review comprehensively explores the impact of advanced concrete types—such as Engineered Cementitious Composites (ECCs), Ultra-High-Performance Concrete (UHPC), High-Performance Concrete (HPC), and polymer concrete—on enhancing the damping behavior. Additionally, key mix design innovations, including fiber reinforcement, rubber powder incorporation, and aggregate modification, are evaluated for their roles in increasing energy dissipation. External factors, particularly curing conditions, are also discussed for their influence on the damping performance. The findings consolidate experimental and theoretical insights into how material composition, mix design, and external treatments interact to optimize dynamic resilience. To guide future research, this paper identifies critical gaps including the need for multi-scale numerical simulation frameworks, standardized damping test protocols, and long-term performance evaluation under realistic service conditions. Advancing work in material innovation, optimized mix design, and controlled curing environments will be essential for developing next-generation concretes with superior vibration control, durability, and sustainability. These insights provide a strategic foundation for applications in seismic-prone and vibration-sensitive infrastructure. Full article

Thermoplastic polyurethane (TPU) combines elastomeric and thermoplastic properties but suffers from insufficient rigidity and strength for structural applications. Herein, we developed novel carbon fiber-reinforced TPU (CF/TPU) composites filaments and utilize melt extrusion for 3D printing to maintain elasticity, while achieving enhanced stiffness and strength through multi scale-the control of fiber content and optimization of printing parameters, reaching a rigid–elastic balance. A systematic evaluation of CF content (0–25%) and printing parameters revealed optimal performance to be at 220–230 °C and 40 mm/s for ensuring proper flow to wet fibers without polymer degradation. Compared with TPU, 20% CF/TPU exhibited 63.65%, 105.51%, and 93.69% improvements in tensile, compressive, and impact strength, respectively, alongside 70.88% and 72.92% enhancements in compression and impact energy absorption. This work establishes a fundamental framework for developing rigid–elastic hybrid materials with tailored energy absorption capabilities through rational material design and optimized additive manufacturing processes. Full article

Short fiber-reinforced polymer composites are extensively used in automotive structural components, such as engine mounts and motor mount brackets, due to their favorable strength-to-weight ratio. For motor mount brackets, accurate structural analysis requires consideration of fiber orientation, as it significantly affects the mechanical behavior of the composite. This study aims to investigate the influence of fiber orientation heterogeneity on the mechanical properties of short fiber-reinforced polymer composites formed by injection molding. The spatial variation of the fiber orientation tensor, which evolves from the gate to the flow end during molding, presents challenges in experimental characterization. To address this, microscale analysis was conducted using injection-molded tensile specimens, followed by mesoscale modeling through representative volume elements (RVEs). Homogenization techniques were applied to predict effective mechanical properties, which were subsequently used to evaluate the performance of actual components at the macroscale. The findings demonstrate the importance of multi-scale modeling in capturing the anisotropic behavior of fiber-reinforced composites and provide a framework for more reliable structural analysis in automotive applications. Full article

This study presents a novel methodology for the real-time characterisation and quantitative assessment of damage in fibre-reinforced polymers (FRPs) using acoustic emission (AE) techniques. While FRPs offer superior mechanical properties for structural applications, their anisotropic nature introduces complex damage mechanisms that are challenging to detect with conventional inspection methods. Our approach advances beyond traditional peak frequency analysis by implementing a multi-variant frequency assessment that can detect and evaluate simultaneously occurring damage modes. By applying the fast Fourier transform and examining multiple frequency peaks within AE signals, we successfully identified five distinct damage mechanisms in carbon fibre composites: matrix cracking (100–200 kHz), delamination (205–265 kHz), debonding (270–320 kHz), fibre fracture (330–385 kHz), and fibre pullout (395–490 kHz). A comparative analysis with wavelet transform methods demonstrated that our approach provides earlier detection of critical damage events, with delamination identified approximately 28 s sooner than with conventional techniques. The proposed methodology enables a more accurate quantitative assessment of structural health, facilitating timely maintenance interventions for large-scale FRP structures, such as wind turbine blades, thereby enhancing reliability while reducing operational downtime and maintenance costs. Full article

In this work, the mechanical properties of jute fiber-reinforced polymers were investigated, considering two manufacturing technologies—wet layups and vacuum-assisted resin infusion—with the aim of developing cost-effective composite materials based on natural fibers. In the manufacturing process, two different types of resins were used, specific to each technology. Specimens measuring 25 mm × 200 mm were cut from the resulting laminates at three orientations (0°, 45° and 90° with respect with the weft orientation), and they were subjected to tensile tests. The results showed that resin infusion yielded superior stiffness and strength values when compared to the wet layup. Multi-scale modeling techniques were applied in order to estimate the properties of the fibers and evaluate the orthotropic properties of the composites, and virtual material models that included orthotropic elasticity and the anisotropic Hill plasticity formulation were developed and evaluated, managing to reproduce the experimental data using finite element analyses with decent accuracy. 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

This paper investigates the effects of the basalt-fiber-reinforced polymer (BFRP) and polyethylene (PE) hybrid fiber ratio on the mechanical properties and durability of engineered cementitious composites (ECC). First, four different PE-BFRP hybrid fiber ECC mixtures were systematically prepared by controlling the fiber volume ratio of PE and BFRP fibers. The workability and mechanical properties of the hybrid fiber ECC (HFECC) were then evaluated using flowability tests and multi-scale mechanical tests, including compressive strength, flexural strength, bending toughness, and tensile performance. After that, the durability of HFECC with different fiber ratios was comprehensively assessed through freeze–thaw cycle tests and rapid ion migration tests. Finally, the interface morphology of fibers within the matrix was observed using scanning electron microscopy (SEM). The results show that an appropriate hybrid of PE and BFRP fibers can synergistically enhance the crack resistance and toughness of ECC, improving its failure mode. The best performance in terms of flowability and mechanical properties was observed for the HFECC mixture with 1.30% PE fiber volume and 0.30% BFRP fiber volume. With the increase in BFRP fiber content, the freeze–thaw resistance and chloride ion erosion resistance of HFECC were gradually enhanced. This study provides experimental and theoretical support for the design and engineering application of high-performance hybrid fiber ECC materials. 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

In the present research work is demonstrated a cross-scale manufacturing approach for the production of multifunctional glass fiber reinforced polymer (GFRP) composite tubes with a purposely redesigned filament winding process. Up until now, limited studies have been reported towards the multiscale reinforcement direction of continuous fibers for the manufacturing of hierarchical composites at the industrial level. This study involved the development of two different multi-walled carbon nanotube (MWCNT) aqueous-based inks, which were employed for the modification of commercial glass fiber (GF) reinforcing tows via a bath coating unit in a pilot production line. The obtained multifunctional GFRP tubes presented a variety of characteristics in relation to their final mechanical, hydrothermal aging, electrical, thermal and thermoelectric properties. Results revealed that the two individual systems exhibited pronounced differences both in crushing behavior and durability performance. Interestingly, for lateral compression the MWCNT coatings comprising a polymeric dispersant minorly affected the mechanical response of the produced tubes. The crashworthiness indicators of the multifunctional tubes displayed a slight 5% variation to the respective reference values, combined with a more ductile behavior. Moreover, regarding the bulk electrical and thermal conductivity values, as well as the Seebeck coefficient factor, the corresponding tubes displayed a variance of 233% and 19% and an opposite semi-conducting sign denoting a p- and n-type character, respectively. Full article