Search Results (87)

Three-dimensionally printed cement-based composites emerge as a research hotspot in the fields of construction engineering in recent years. Current research primarily focuses on the reinforcement mechanisms of individually incorporated fibres, while a significant gap remains in the synergistic effects of hybrid fibre systems. This study investigates the effects of mono-doping (0.2 wt.% and 0.4 wt.% by the mass of the cement) and hybrid-doping (0.1 wt.% + 0.1 wt.% by the mass of the cement) with 3 mm polypropylene, basalt, and carbon fibres on the fresh-state properties and mechanical behaviours. Through quantitative characterisation of the flowability and mechanical performance of short-fibre-reinforced 3D-printed cementitious composites (SFR3DPC), coupled with comprehensive testing including digital image correlation, X-ray diffraction, and scanning electron microscopy, several key findings are obtained. The experimental results indicate that the addition of excess fibres reduces fluidity, which affects the mechanical performance and make the anisotropy of the composites more pronounced. While the single addition of 0.2 wt.% CF shows the most significant improvement in flexural and compressive strengths, the hybrid combination of 0.1 wt.% CF and 0.1 wt.% BF shows the greatest increase in interlayer bond strength by 26.7%. The complementary effect of the hybrid fibres contributes to the damage mode of the composites from brittle fracture to quasi-brittle behaviour at the physical level. These findings offer valuable insights into optimising the mechanical performance and improving defects of 3D-printed cementitious composites with short fibres. Full article

Nylon reinforced with short carbon fibres exhibits superior mechanical properties. Its use as a feedstock for fused deposition modelling (FDM) can extend its applications to consumer goods and industrial products. To investigate the flexural and impact properties of the FDM-printed short carbon fibre-reinforced nylon, a central composite face-centred (CCF) design with four factors and three levels and the response surface method (RSM) were employed. The four primary process parameters are the extrusion and bed temperatures, printing speed, and layer thickness. The three investigated responses were the flexural strength, flexural modulus, and impact strength. Perturbation curves and contour plots were used to analyse the influences of the individual and two-way interactions of the response parameters, respectively. Second-order statistical models were constructed to predict and optimise the mechanical properties. The optimal comprehensive mechanical properties were determined using a desirability function combined with the entropy weighting method. The predicted results of best comprehensive mechanical properties are 169.881 MPa for the flexural strength, 9249.11 MPa for the flexural modulus, and 29.659 kJ∙m⁻² for the impact strength, achieved under the parameter combination of extrusion temperature of 318 °C, bed temperature of 90 °C, printing speed of 30 mm∙s⁻¹, and layer thickness of 0.1 mm. A small deviation between the predicted and experimental results indicated the high reliability of the proposed method. The optimal outcomes under the studied parameters showed higher robustness and integrity than previously reported results. Full article

The mechanical properties of additive manufactured (AM) short-fibre reinforced polymer (SFRP) composites are significantly influenced by infill patterns, fibre orientation, and fibre-matrix interactions. While previous studies have explored the role of process parameters in optimising AM components, the impact of infill geometry on anisotropy and mechanical performance remains underexplored, particularly in the context of machine learning (ML). This study develops an ML-driven framework to predict the tensile and flexural properties of AM SFRP composites with different infill patterns, including triangular, hexagonal, and rectangular. AM structures were fabricated and subjected to tensile and flexural tests, with the data used to train ML models, including LightGBM, XGBoost, and artificial neural networks (ANN). The results showed that the triangular infill pattern had the highest tensile strength and stiffness, the hexagonal infill had the lowest flexural properties, and the rectangular infill exhibited performance levels that fell between those of the triangular and hexagonal patterns. The ML models demonstrated high prediction accuracy, with R-squared values exceeding 0.95. XGBoost performed best for predicting tensile properties of hexagonal infill, while ANN excelled with triangular and rectangular configurations. This study demonstrates the potential of machine learning to enhance the mechanical performance of additively manufactured SFRP composites by capturing the complex interplay between infill geometry and fibre-matrix interactions. Thus, providing additional data for the design of high-performance materials in applications such as biomedical devices. Full article

The development of lightweight construction is of crucial importance for the development of sustainable technologies and for the reduction in carbon dioxide emissions, especially in the automotive industry. This study aims to address the challenges associated with manufacturing plant fibre-based polymer composites. The investigation focused on two novel formulations of bio-based unsaturated polyester resins, assessing their viability as a matrix in plant fibre-reinforced composites within the context of automotive applications. The study addresses the challenges related to the preparation and processing of the system, leading to the necessity of diluting the resin with (hydroxymethyl)methacrylate (HEMA) to achieve an applicable viscosity. Two different flax fibre textiles, in the form of a short fibre mat and a woven fabric, were used as reinforcement. The composite panels were manufactured using the vacuum-assisted resin infusion (VARI) process. The most efficacious material combination, comprising Bcomp^® ampliTex™ 5040 and STRUKTOL^® POLYVERTEC^® 3831, with viscosity modified by 39% HEMA, exhibited a consistent fibre volume fraction of 40% and a glass transition temperature of 70 °C. In addition, the mechanical behaviour in the 0°-direction demonstrated tensile strength and modulus values of approximately 99 MPa and 9 GPa, respectively, accompanied by an elongation at break of 2%. The flexural modulus was found to be 7 GPa, and the flexural strength 94 MPa. Full article

The present study utilises the extended finite element method (XFEM) to model fibre-reinforced composites, with a focus on crack initiation and propagation. Silicon nitride-based ceramics were selected as a model material; they represent a broad class of short fibre ceramics and have received a lot of attention in recent decades. Some peculiarities when using the XFEM, including its selected modifications, are discussed in response to applied external stresses, mainly in the viscoelastic range. Promising approaches are recommended, which lead to a more accurate description of these materials under operating conditions, focusing on the correct calculation of the macroscopic stress ahead of the propagating crack front. The authors draw on years of experience with the material and investigate the possible improvements and modifications to the XFEM. Full article

Comprehensive analysis of the anisotropic nature of additively manufactured (AM) parts caused by their fabrication method requires attention, as current quasi-static experiments on AM specimens are used to determine strength and stiffness. This study investigates the anisotropic mechanical behaviour of AM polymer composites reinforced with short and continuous carbon fibres, examining various filament orientations, loading directions and strain rates. Utilising the fused deposition modelling (FDM) technique, nylon and carbon fibres were fabricated into composites with controlled orientations. Mechanical tests were conducted in different directions to assess the tensile and compressive properties of these composites, with results showing enhanced tensile strength and stiffness in continuous-fibre (CF) composites compared to short-fibre (SF) ones, particularly in longitudinal orientations. The compressive behaviour revealed complex effects of type and orientation of reinforcing fibres, with CF composites demonstrating superior stiffness but lower strength than SF composites in specific orientations. Strain rate sensitivity analysis for the least anisotropic (quasi-isotropic) cases indicated that tensile strength decreased slightly with the increased strain rate while compressive strength increased. These findings underline the critical effect of fibre orientation and type on mechanical properties and suggest potential applications of AM composites in scenarios demanding tailored anisotropic behaviours, including structural optimisation and numerical modelling for various loading conditions. Full article

Wood–polymer composites and composites reinforced with natural and man-made cellulose fibres are being extensively used in the automotive and building industries. The main shortcoming of the former is their low-impact resistance and brittleness. The relatively high cost of natural and cellulose fibres is the limitation of the latter. This research uses a hybrid combination of wood flour and short man-made cellulose fibres to develop polypropylene composites for injection moulding that excel in mechanical characteristics and have low material cost. Both reinforcements are of wood origin. The synergistic hybrid effect of this combination of reinforcements helps to achieve their mechanical performance superior to that of wood–polymer composites at preserved low cost. The proposed Response Surface Methodology enables the calculation of necessary weight fractions of two reinforcements to achieve desired mechanical properties like strength, tensile, flexural modulus, and impact resistance. Full article

The advancement of 3D printing technology has changed material design and fabrication across various industries. Among its many applications, the development of high-wear-resistance polymer composites, particularly using Fused Deposition Modelling (FDM), has received increasing interest from both academic and industrial sectors. This paper provides an overview of recent advances in this field, focusing on the selection of key printing parameters (such as layer thickness, print speed, infill density, and printing temperature) and material compatibility optimisation to enhance print quality and tribological performance. The effects of various tribo-fillers, such as fibres and nanoparticles, on the tribological properties of the printed polymer composites were studied. Generally, in the case of nano-sized particles, the wear rate can be reduced by approximately 3 to 5 times when the nanoparticle content is below 5 vol.%. However, when the nanoparticle concentration exceeds 10 vol.%, wear resistance may deteriorate due to the formation of agglomerates, which disrupts the uniform dispersion of reinforcements and weakens the composite structure. Similarly, in short fibre-reinforced polymer composites, a fibre content of 10–30 vol.% has been observed to result in a 3 to 10 times reduction in wear rate. Special attention is given to the synergistic effects of combining micro- and nano-sized fillers. These advancements introduce novel strategies for designing wear-resistant polymer composites without requiring filament fabrication, making 3D printing more accessible for tribological applications. In the last part of the review, the impact of emerging AI technologies on the field is also reviewed and discussed. By identifying key research gaps and future directions, this review aims to drive further innovation in the development of durable, high-performance materials for wide industry applications in aerospace, biomedical, and industrial engineering. Full article

Polyamide-based glass fibre-reinforced composites are extensively used in electrical and automotive applications due to their excellent mechanical, thermal, and electrical properties. However, prolonged exposure to high temperatures can lead to significant degradation, affecting their long-term performance and reliability. This study investigates the thermal ageing behaviour of polyamide 6,6 composites containing halogenated flame retardants used for electrical applications. The objective of this research is to evaluate the extent of degradation through accelerated ageing tests and to develop an Arrhenius-type ageing model to predict the long-term performance of these materials. This study examines the effects of thermal ageing at temperatures between 160 and 210 °C on flexural properties and explores the underlying degradation mechanisms. Results indicate that short-term exposure to high temperatures can enhance flexural strength due to annealing effects, which are eventually outweighed by thermal oxidation and increased crystallinity, leading to an increase in brittleness. The derived Arrhenius model, with an activation energy of 93 kJ/mol, predicts a service life of approximately 25 years at 80 °C, but a significantly shorter one at 130 °C. These findings underscore the importance of considering thermal ageing effects in the design and application of PA66 composites in high-temperature environments. Full article

The use of fibre-reinforced concrete (FRC) has been substantially increasing in the last few years, in different fields of the construction industry. Recently, many experiments have been performed to observe the short- and long-term mechanical behaviour of FRC, and several models have been formulated to capture its mechanical response. In this work, the mechanical behaviour is simulated through the Lattice Discrete Particle Model (LDPM) and its extension to fibre-reinforced cementitious composites (LDPM-F). This paper aims to provide insights into the calibration process and potential pitfalls in a case where only limited experimental data are available—in this case, unconfined uniaxial compression and three-point bending tests on different mixes of polypropylene and steel fibre-reinforced concretes. As a first step, a sensitivity analysis is performed to weight the effect of each governing mesoscale parameter on the simulated macroscale behaviour. Then, for each mix at issue, different sets of model parameters are identified as capable of accurately matching the experimental evidence. As a validation, each calibrated set is used to simulate energy absorption tests on round panels. The validation stage shows that one of the identified sets, for the FRC with polypropylene fibres, accurately matches the round panels’ response, while the others result in acceptable predictions. For the mix with steel fibres, instead, none of the sets captures the experimental results, likely due to the different post-cracking behaviour detected in fracture and energy absorption tests. Finally, a parametric study showcases how the LDPM-F might serve as tool to optimise the mix design without extensive experimental investigations. Full article

This study investigates the quasi-static and viscoelastic properties of additively manufactured (AM) PETG reinforced with short carbon fibres. Samples were manufactured using different parameters in terms of the infill pattern, porosity, and annealing condition. Tensile and compressive tests were conducted to determine quasi-static properties such as Young’s modulus and toughness, and dynamic mechanical analysis was used under a frequency sweep of 1–100 Hz to describe the viscoelastic behaviour of the composites. The major impacts and responses between the print parameters were quantified using Analyses of Variance (ANOVAs), which revealed the major contributor to each mechanical property. Fractography on the tensile samples using scanning electron microscopy demonstrated fibre pull-out, indicating poor fibre–matrix bonding, but also revealed interfacial bonding between raster lines in the annealed samples. This had a prominent effect on the properties of latitudinal samples where the force applied was perpendicular to the raster lines. Generally, porosity appeared to have the greatest contribution to the variance in the mechanical properties, with the exception of the tensile modulus, where the infill pattern had a more substantial effect. Annealing caused a consistent increase in the tensile modulus of the tested samples, which can be used to support the design and optimisation of AM parts when they are used under specific loading conditions. Full article

The development of dental materials needs to be supported with sound evidence. This in vitro study aimed to measure the fracture toughness of a short fibre-reinforced composite (sFRC), at differing thicknesses. In this study, 2 mm, 3 mm and 4 mm depths of sFRC were prepared. Using ISO4049, each preparation was tested to failure. A total of 60 samples were tested: 10 samples for each combination of sFRC and depth. Fractured samples were viewed, and outcomes were analysed. EXF showed greater toughness than EXP, with a mean of 2.49 (95%CI: 2.25, 2.73) MPa.m^1/2 compared to a mean of 2.13 (95%CI: 1.95, 2.31) MPa.m^1/2, (F(1,54) = 21.28; p < 0.001). This difference was particularly pronounced at 2 mm depths where the mean (95%CI) values were 2.72 (2.49, 2.95) for EXF and 1.90 (1.78, 2.02) for EXP (Interaction F(2,54) = 7.93; p < 0.001). Both materials performed similarly at the depths of 3 mm and 4 mm. The results for both materials were within the accepted fracture toughness values of dentine of 1.79–3.08 MPa.m^1/2. Analysis showed crack deflection and bridging fibre behaviour. The optimal thickness at the cavity base for EXF was 2 mm and for EXP 4 mm. Crack deflection and bridging behaviour indicated that restorations incorporating sFRCs are not prone to catastrophic failure and confirmed that sFRCs have similar fracture toughness to dentine. sFRCs could be a suitable biomimetic material to replace dentine. Full article

Ultrasonic welding of fibre-reinforced thermoplastics is a joining technology with high potential for short welding times and low energy consumption. While the majority of the current studies on continuous ultrasonic welding have so far focused on woven reinforcements, unidirectional materials are preferred for highly loaded aerospace components due to their better mechanical performance. Therefore, this paper investigates the influence and interdependence of the welding speed, amplitude, and energy director thickness on the weld quality of adherends made of unidirectional composites. The quality of the welded joints is assessed by a single-lap shear strength and fracture surface analysis complemented by the microscopic analysis of cross-sections and comparison to a co-consolidated reference. The results showed that the welding process is highly affected by changing welding speeds for a given amplitude. Furthermore, while lower amplitudes lead to significant scatter in the welding quality, higher amplitudes result in increased heating rates and a fully molten energy director even for high welding speeds. Nevertheless, insufficient consolidation at high welding speeds results in porosity in the weld line. Finally, it was observed that thicker, and therefore more compliant, energy directors lead to more uniform melting of the energy director and less deviation in the weld quality for a wider range of welding speeds. Full article

Tidal energy, with its potential to provide a consistent energy output and reduce carbon emissions, has garnered significant interest. This study, which evaluates the performance of tidal turbine blades in seawater conditions and with sand particles, presents a novel approach. A slurry rig was developed to examine composite materials, and a glass fibre-reinforcement polymeric material was tested over a range of particle sizes, velocities, and impact angles. In addition, this paper used a new test protocol with 14 days (336 h) and 91 days (2184 h) of pre-exposure time of materials before testing. The results, which show significant changes in the erosive mechanisms of GFRP in short- and long-term pre-exposure time as a function of these variables, have profound implications for the design and performance of tidal turbine blades. The study also utilised scanning electron microscopy (SEM), depth profiling analysis, and erosion mapping techniques to compare the erosion behaviours of GFRP. These tools can be used to optimise such materials in tidal turbine conditions. Full article

This study investigates the printability limitations of 3D-printed continuous 316L stainless steel fibre-reinforced polymer composites obtained using the Materials Extrusion (MEX) technique. The objective was to better understand the geometric printing limitations of composites fabricated using continuous steel fibres, based on a combination of bending stiffness testing and piezoresistive property studies. The 0.5 mm composite filaments used in this study were obtained by co-extruding polylactic acid (PLA), with a 316 L stainless steel fibre (SSF) bundle. The composite printability limitations were evaluated by the printing of a series of ’teardrop’ shaped geometries with angles in the range from 5° to 90° and radii between 2 and 20 mm. The morphology and dimensional measurements of the resulting PLA-SSF prints were evaluated using $\mu$CT scanning, optical microscopy, and calliper measurements. Sample sets were compared and statistically examined to evaluate the repeatability, turning ability, and geometrical print limitations, along with dimensional fluctuations between designed and as-printed structures. Comparisons of the curvature bending stiffness were made with the PLA-only polymer and with 3D-printed nylon-reinforced short and long carbon fibre composites. It was demonstrated that the stainless steel composites exhibited an increase in bending stiffness at smaller radii. The change in piezoresistance response of the PLA-SSF with load applied during the curvature bending stiffness testing demonstrated that the 3D-printed composites may have the potential for use as structural health monitoring sensors. Full article