Search Results (16)

This research paper employed novel sustainable alternative materials to reduce the environmental impact of thermoset/synthetic fibre composites. The effect of seawater hydrothermal ageing at 45 °C for 45 and 90 days on the physical and interlaminar fracture toughness (mode I and mode II) of a semi-unidirectional non-crimp basalt fibre (BF)-reinforced acrylic matrix and epoxy matrix composites was investigated. Optical and scanning electron microscopes were used to describe the fracture and interfacial failure mechanisms. The results show that the BF/Elium composite exhibited higher fracture toughness properties compared to the BF/Epoxy composite. The results of the mode I and mode II interlaminar fracture toughness values for the BF/Elium composite were 1280 J/m² and 2100 J/m², which are 14% and 56% higher, respectively, than those of the BF/Epoxy composite. The result values for both composites were normalised with respect to the density of each composite laminate. The saturated moisture content and diffusion coefficient values of seawater-aged samples at 45 °C and room temperature for the BF/Elium and BF/Epoxy composites were analysed. Both composites exhibited signs of polymer matrix decomposition and fibre surface degradation under the influence of seawater hydrothermal ageing, resulting in a reduction in the mode II interlaminar fracture toughness values. Enhancement was observed in mode I fracture toughness under hydrothermal ageing, particularly for the BF/Epoxy composite, due to matrix plasticisation and fibre bridging. Full article

A fabric orientation angle has a significant influence on the failure mechanisms at the lamina level. Any change in this angle can lead to a sudden reduction in strength, potentially resulting in catastrophic failures due to variations in load-carrying capacity. This study examined the impact of off-axis fabric orientation angles (0°, 15°, 30°, 45°, 60°, and 90°) on the flexural properties of non-crimp basalt-fibre-reinforced acrylic thermoplastic composites. The basalt/Elium^® composite panels were manufactured using a vacuum-assisted resin transfer moulding technique. The results show that the on-axis (0°) composite specimens exhibited linear stress–strain behaviour and quasi-brittle failure characterised by fibre dominance, achieving superior strength and failure strain values of 1128 MPa and 3.85%, respectively. In contrast, the off-axis specimens exhibited highly nonlinear ductile behaviour. They failed at lower load values due to matrix dominance, with strength and failure strain values of 144 MPa and 6.0%, respectively, observed at a fabric orientation angle of 45°. The in-plane shear stress associated with off-axis angles influenced the flexural properties. Additionally, the degree of deformation and the fracture mechanisms were analysed. Full article

Due to their improved recyclability, thermoplastic composites (TPCs) are increasing their application across industries. The current work deals with the dimensioning, manufacturing, and characterisation of vacuum-infused TPCs cured at RT and made of non-crimp glass fabric and the liquid acrylic-based resin Elium©. Laminates with 10 and 12 layers achieved a fibre weight content of 73% measured by the burn-off process, which corresponds to a fibre volume content of 55%. Three-point bending tests revealed a bending strength of 636.17 ± 25.70 MPa and a bending modulus of 24,600 ± 400 MPa for the 12 layer laminate. Using micro-mechanical models, unidirectional elastic constants are calculated and applied in classical laminate theory (CLT) for optimising composite lay-ups by maximising bending stiffness, whilst yielding a laminate thickness prediction error of −0.18% and a bending modulus prediction error of −1.99%. Additionally, FEA simulations predicted the bending modulus with a −4.47% error and illustrated, with the aid of the Tsai–Hill criterion, the relationship between the onset of layer failure and discrepancies between experimental results and simulations. This investigation demonstrates the effective application of analytical and numerical methods in the dimensioning and performance prediction of TPCs. Full article

Fibres in different textile forms (woven, knitted, stitched, and non-crimp) are used to reinforce composites for multifaced applications, including automotive, aerospace, marine, rail, energy, construction, and defence sectors. Textile fabric-based fibre reinforcements for composites possess some outstanding features, such as good dimensional stability, subtle conformability, deep draw moldability/processability, lightweightness, high strength and stiffness, and low cost. The greatest advantage of textile fibre-reinforced composites is the freedom to tailor their strength and stiffness properties for specific applications. Therefore, the design of composites involves defining the fabric geometry, stacking sequence, and orientation of fibres to optimise the system. Compared to knitted, stitched, and non-crimp fabrics, woven fabric-based fibre-reinforced composites are widely used in the industry. The properties of woven fabric-reinforced composites depend on several factors, such as types of fibre, compositions, polymeric matrices, and fibre/matrix interfacial strength. Some of the advantages are reduced preforming process steps, good impact and delamination resistance, and thermo-mechanical properties. This review has been written to provide detailed information and discussions, including the fabrication processes, relationship between fabric structure and composite properties, and morphological characteristics encompassing the current state-of-the-art in woven fabrics for composite reinforcement. Full article

Textile polymer composite is made of structured fibre matrix using textile technologies in fabrication, and gains benefits from strong mechanical properties with extra light weight. However, erosion behaviours and associated wear mechanisms of the composites may be influenced by the fibre structures due to heterogeneous composition and complex architectural topologies. Understanding the erosive mechanisms of the structured composites can be important, not only for preventing surface damage and loss of mechanical strength but also for improving design and fabrication of the composites. This paper presents an experimental study of erosive wear under sand blasting on 3D woven carbon-fibre-reinforced textile composites with epoxy. The architectural topology methods of the composites include non-crimped bidirectional, tufted bidirectional, 3D layer-to-layer and 3D orthogonal textile methods. The erosion tests were conducted on four impact angles (20°, 30°, 45° and 90°) under one impact velocity at 40 m/s. The study results show that the erosive mechanism of the textile composites is different from that of the neat substrate material. The observations from this study also reveal the different erosive behaviours between the composites with different fibre structures. It concludes that architectural structures can influence the erosion of a textile composite but will not result in significant differences in the wear resistance of the composites (<20%). Full article

Sixteen-head automatic tape laying of non-crimped carbon-fibre-reinforced plastic is performed, and the fibre alignment is compared with that produced via hand laying. The effect of fibre alignment is tested via quasi-static and cyclic three-point bending tests. Using the Fill Multilayer (a 16-head tape-laying machine), precision fibre laying of unidirectional fabrics is performed with deliberate misalignment to examine the effect of fibre orientation and investigate the random effect on longitudinal misalignment. The automatic tape-layered coupons are compared with hand-layered carbon fibre tapes to investigate the relationship between the fibre alignment and the flexural strength. A 52% reduction in the fibre alignment scatter is achieved via the Fill Multilayer. Fibre orientation increases lead to a higher flexural strength of 16.08% for Fill Multilayer-made coupons compared with hand-layered samples. An investigation of the correlation between fibre alignment and flexural strength shows that shear-based failure increases exponentially as the alignment decreases. Fill Multilayer-made coupons have a higher void concentration due to ultrasonic welding, but also the highest modulus and flexural strength, as fibre misalignment is reduced to 1.68°, with a modulus degradation of 1.4%. Full article

Textile composites are predestined for crash-loaded lightweight structures due to their adjustable energy absorption capacity, but they can exhibit different types of defects that occur during production (voids) and in operation (fatigue). The influence of such defects, especially the interaction of several defect types on the strain-rate-dependent material behaviour, is still insufficiently researched and can represent a safety risk. Therefore, this paper presents a phenomenological model that can be used to mathematically describe the strain-rate-dependent stress-strain behaviour of nominally defect-free and defect-affected textile composites. An adjunctive damage model in the sense of continuum damage mechanics is introduced, which also considers the interaction of both defect types for the first time. For the model validation, extensive experimental tests on glass fibre non-crimp fabrics reinforced epoxy (GF-NCF/EP) composites are performed. The focus is put on the influence of voids and fatigue-related pre-damage under subsequent tensile loading at strain rates up to 40 s${}^{-1}$. The theoretical studies show a good coincidence with the experimental results. The novel model provides a method for the efficient generation of material maps for numerical highly dynamic crash and impact analyses for defect-free and defective textile composites. As a result, a flexible and practice-oriented model approach is available, which makes a significant contribution to an improved understanding of materials and enables a future defect-tolerant design of textile composites. Full article

Delamination, a form of composite failure, is a significant concern in laminated composites. The increasing use of out-of-autoclave manufacturing techniques for automotive applications, such as compression moulding and thermoforming, has led to increased interest in understanding the delamination resistance of carbon-fibre-reinforced thermoplastic (CFRTP) composites compared to traditional carbon-fibre-reinforced thermosetting (CFRTS) composites. This study evaluated the mode I (opening) interlaminar fracture toughness of two non-crimp fabric (NCF) biaxial (0/90°) carbon/thermoplastic composite systems: T700/polyamide 6.6 and T700/polyphenylene sulphide. The mode I delamination resistance was determined using the double cantilever beam (DCB) specimen. The results were analysed and the Mode I interlaminar fracture toughness was compared. Additionally, the fractographic analysis (microstructure characterisation) was conducted using a scanning electron microscope (SEM) to examine the failure surface of the specimens. Full article

The analysis of fibrous structures using micro-computer tomography (µCT) is becoming more important as it provides an opportunity to characterise the mechanical properties and performance of materials. This study is the first attempt to provide computations of fibre crimp for various random fibrous networks (RFNs) based on µCT data. A parametric algorithm was developed to compute fibre crimp in fibres in a virtual domain. It was successfully tested for six different X-ray µCT models of nonwoven fabrics. Computations showed that nonwoven fabrics with crimped fibres exhibited higher crimp levels than those with non-crimped fibres, as expected. However, with the increased fabric density of the non-crimped nonwovens, fibres tended to be more crimped. Additionally, the projected fibre crimp was computed for all three major 2D planes, and the obtained results were statistically analysed. Initially, the algorithm was tested for a small-size, nonwoven model containing only four fibres. The fraction of nearly straight fibres was computed for both crimped and non-crimped fabrics. The mean value of the fibre crimp demonstrated that fibre segments between intersections were almost straight. However, it was observed that there were no perfectly straight fibres in the analysed RFNs. This study is applicable to approach employing a finite-element analysis (FEA) and computational fluid dynamics (CFD) to model/analyse RFNs. Full article

Geopolymer concrete is one of the innovative eco-friendly materials that has gained the attention of many researchers in the sustainable development of the construction industry. The primary objective of this experimental investigation is to study the flexural behaviour of the ternary blend geopolymer concrete (TGPC) with various proportions of hybrid fibres. In this study, 27 reinforced concrete beams were cast with a TGPC grade of M55 and tested under monotonic loading conditions. The specimens were beams of length 1200 mm, depth of 150 mm, and width of 100 mm. Crimped steel (metallic) fibres and polypropylene (non-metallic) fibres were used in hybrid form to study the effect on the TGPC beams under flexure. The volume fractions of steel fibres were varied up to 1% with an increment of 0.5%, and polypropylene fibres varied from 0.1% to 0.25% with an increment of 0.05%. The test results were analysed based on the first crack load, ultimate load, load-deflection behaviour, energy absorption capacity, moment-curvature relationship, and ductility behaviour and compared with TGPC specimens without fibres. The experimental study reveals that the TGPC is one of the best alternatives for conventional cement concrete. The addition of hybrid fibres potentially improves the flexural properties of TGPC to a great extent. The test results showcased that the HTGPC with 1% steel and 0.1% polypropylene fibres exhibited better flexural properties than the other combinations of hybrid fibres considered in this study. Additionally, an effort was made to develop a model to estimate the flexural strength of TGPC with hybrid fibres, and the predicted values were found satisfactorily with the test results. Full article

The present study provides a correlation and regression analysis of lightweight waste aggregate concretes with varying degrees of fibre reinforcement. The concrete mix contains pre-soaked red ceramic waste aggregate, expanded clay coarse aggregate and Portland cement. Copper-coated crimped steel fibre was used as the reinforcement. The experimental results included properties measured by destructive test methods—compressive strength, splitting tensile strength, static modulus of elasticity, the limit of proportionality, shear strength; and by non-destructive test methods—dynamic modulus of elasticity and surface electrical resistivity. These properties were analysed to study the relevancy and significance between non-destructive and destructive methods of measurement in the case of different amounts of fibre. The results show differences in the degree of fit to the linear and quadratic regression curves for pairs of destructive and non-destructive test results. As expected, the linear relationship can be applied in a few cases, but the quadratic curve must be used for a few pairs. Another observation is that it is not possible to neglect the amount of fibre in the correlation analyses of the measured properties. Full article

This work developed novel jute-yarn, non-crimp, unidirectional (UD) preforms and their composites, with three different types of warp jute yarns of varying linear densities and twists in the dry UD preforms, in order to present a possible solution to the detrimental effects of higher yarn twists and crimp at the warp–weft yarn interlacements of traditional, woven, preform-based composites on their mechanical properties. In the developed UD preforms, warp jute yarns were placed in parallel by using a wooden picture-frame pin board, with the minimal number of glass weft yarns to avoid crimp at the warp–weft yarns interlacements, which can significantly enhance the load-bearing ability of UD composites compared to traditional, woven, preform composites. It was found that an optimal combination of jute warp yarn linear densities and twists in the UD preforms is important to achieve the best possible mechanical properties of newly developed UD composites, because it encourages a proper polymer-matrix impregnation on jute fibres, leading to excellent fibre–matrix interface bonding. Composites made from the 25 lb/spindle jute warp yarn linear density (UD25) exhibited higher tensile and flexural properties than other UD composites (UD20, UD30). All the UD composites showed a much better performance compared to the traditional woven preform composites (W20), which were obviously related to the higher crimp and yarn interlacements, less load-carrying capacity, and poor fiber–matrix interfaces of W20 composites. UD25 composites exhibited a significant enhancement in tensile modulus by ~232% and strength by ~146%; flexural modulus by 138.5% and strength by 145% compared to W20 composites. This reveals that newly developed, non-crimp, UD preform composites can effectively replace the traditional woven composites in lightweight, load-bearing, complex-shaped composite applications, and hence, this warrants further investigations of the developed composites, especially on long-term and dynamic-loading mechanical characterizations. Full article

There has been a lot of interest in understanding the low-velocity impact (LVI) response of thermoplastic composites. However, little research has focussed on studying the impact behaviour of non-crimp fabric (NCF)-based fibre reinforced thermoplastic composites. The purpose of this study was to evaluate the LVI responses of two types of non-crimp fabric (NCF) carbon fibre reinforced thermoplastic laminated composites that have been considered attractive in the automotive and aerospace industry: (i) T700/polyamide 6.6 (PA6.6) and (ii) T700/polyphenylene sulphide (PPS). Each carbon/thermoplastic type was impacted at three different energy levels (40, 100 and 160 J), which were determined to achieve three degrees of penetrability, i.e., no penetration, partial penetration and full penetration, respectively. Two distinct non-destructive evaluation (NDE) techniques ((i) ultrasonic C-scanning and (ii) X-ray tomography) were used to assess the extent of damage after impact. The laminated composite plates were subjected to an out-of-plane, localised impact using an INSTRON^® drop-weight tower with a hemispherical impactor measuring 16 mm in diameter. The time histories of force, deflection and velocity are reported and discussed. A nonlinear finite element model of the LVI phenomenon was developed using a finite element (FE) solver LS-DYNA^® and validated against the experimental observations. The extent of damage observed and level of impact energy absorption calculated on both the experiment and FE analysis are compared and discussed. Full article

The effect of the weaving architecture and the z-binding yarns, for 2D and 3D woven composites on the low-velocity impact resistance of carbon fibre reinforced composites, is investigated and benchmarked against noncrimp fabric (NCF). Four architectures, namely: NCF, 2D plain weave (2D-PW), 3D orthogonal: plain (ORT-PW) and twill (ORT-TW), were subjected to 15 J impact using a 16 mm-diameter, 6.7 kg hemispherical impactor. Nondestructive techniques, including ultrasonic C-scanning, Digital Image Correlation (DIC) and X-ray computed tomography (CT) were used to map and quantify the size of the induced barely visible impact damage (BVID). The energy absorption of each architecture was correlated to the damage size: both in-plane and in-depth directions. The 3D architectures, regardless of their unit-cell size, demonstrated the highest impact resistance as opposed to 2D-PW and the NCF. X-ray CT segmentation showed the effect of the higher frequency of the z-binding yarns, in the ORT-PW case, in delamination and crack arresting even when compared to the other 3D architecture (ORT-TW). Among all the architectures, ORT-PW exhibited the highest damage resistance with the least damage size. This suggests that accurate design of the z-binding yarns’ path and more importantly its frequency in 3D woven architectures is essential for impact-resistant composite structures. Full article

Understanding the fatigue damage mechanisms in composite materials is of great importance in the wind turbine industry because of the very large number of loading cycles rotor blades undergo during their service life. In this paper, the fatigue damage mechanisms of a non-crimp unidirectional (UD) glass fibre reinforced polymer (GFRP) used in wind turbine blades are characterised by time-lapse ex-situ helical X-ray computed tomography (CT) at different stages through its fatigue life. Our observations validate the hypothesis that off-axis cracking in secondary oriented fibre bundles, the so-called backing bundles, are directly related to fibre fractures in the UD bundles. Using helical X-ray CT we are able to follow the fatigue damage evolution in the composite over a length of 20 mm in the UD fibre direction using a voxel size of (2.75 µm)³. A staining approach was used to enhance the detectability of the narrow off-axis matrix and interface cracks, partly closed fibre fractures and thin longitudinal splits. Instead of being evenly distributed, fibre fractures in the UD bundles nucleate and propagate locally where backing bundles cross-over, or where stitching threads cross-over. In addition, UD fibre fractures can also be initiated by the presence of extensive debonding and longitudinal splitting, which were found to develop from debonding of the stitching threads near surface. The splits lower the lateral constraint of the originally closely packed UD fibres, which could potentially make the composite susceptible to compressive loads as well as the environment in service. The results here indicate that further research into the better design of the positioning of stitching threads, and backing fibre cross-over regions is required, as well as new approaches to control the positions of UD fibres. Full article