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1. MECHANICAL BEHAVIOR MODELING OF UNIDIRECTIONAL CARBON FIBER REINFORCED POLYMER COMPOSITES REINFORCED WITH Z-DIRECTIONAL NANOFIBERS

   Fariborz Bayat, Kuang-Ting Hsiao (May 2018, International SAMPE Symposium and Exhibition)

   This paper utilizes a periodic unit cell modeling technique combined with finite element analysis (FEA) to predict and understand the mechanical behaviors of a nanotechnology-enhanced carbon fiber reinforced polymers (CFRPs) composite. This research specifically focuses on the study of novel Z-threaded CFRPs (ZT-CFRPs) that are reinforced not only by unidirectional carbon fibers but also with numerous carbon nanofibers (CNFs) threading through the CFRP laminate in the z-direction (i.e., through-thickness direction). The complex multi-scaled orthogonally-structured carbon reinforced polymer composite is modeled starting from a periodic unit cell, which is the smallest periodic building-block representation of the material. The ZT-CFRP unit cell includes three major components, i.e., carbon fibers, polymer matrix, and carbon nanofiber Z-threads. To compare the mechanical behavior of ZT-CFRPs against unmodified, control CFRPs, an additional unit cell without CNF reinforcement was also created and analyzed. The unit cells were then meshed into finite element models and subjected to different loading conditions to predict the interaction among all their components. The elastic moduli of both unit-cells in the z-direction were calculated from the FEA data. By assuming the CNFs have the same mechanical properties of T-300 carbon fiber, the numerical modeling showed that the ZT-CFRPs exhibited a 14% improvement in z-directional elastic modulus due to the inclusion of 1 wt% CNF z-threads, indicating that ZT-CFRPs are stiffer compared to control CFRPs consisting of T-300 carbon fibers and epoxy. 

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2. Fiber and Monomer Recovery from an Amine-Cured Epoxy Composite Using Molten NaOH-KOH

   https://doi.org/10.1039/D4GC05299D  

   Lim, Y Justin; Yu, Zehan; Cherepakhin, Valeriy; Williams, Travis; Nutt, Steven (December 2024, Green Chemistry)

   We report a rapid route to reclaim carbon fiber (CF) fabric and monomeric chemicals from amine-epoxy CF-reinforced polymer (CFRP) composites. We use a reaction that occurs in molten NaOH- KOH eutectic to selectively cleave aryl ether and amine linkages, which involves two temperature-dependant mechanisms. Bisphenol-A is isolated in up to quantitative yields, and recovered CF fabric is remanufactured into 2nd-generation CFRPs. 

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3. IN-SITU BENDING PERFORMANCE OF NANOSTRUCTURED CARBON FIBER REINFORCED POLYMER COMPOSITES

   https://doi.org/10.12783/asc37/36507  

   KAYNAN, OZGE; FALLAHI, HAMED; JARRAHBASHI, DORRIN; ASADI, AMIR (September 2022, Proceedings Of The American Society for Composites-Thirty-Seventh Technical Conference)

   Depositing carbon nanotubes (CNTs) into carbon fiber reinforced polymer composites (CFRPs) is challenging because of the need for complicated lab-scale processes and toxic chemical dispersants that makes conventional means of processing less compatible with existing industrial procedures for large-scale applications. In this work, a scalable supercritical CO2-assisted atomization technique is used to effectively deposit hybrid CNTs in CFRPs allowing them to boost their functionality and tailor the microstructure. Cellulose nanocrystals (CNCs) are utilized to create hybrid nanostructures with CNTs (CNC bonded CNT) that enables stabilization of CNTs in nontoxic media, i.e., water, and this promotes the scalability of the process. According to Zeta potential values, CNCs successfully stabilize CNTs in water suspension. Scanning electron microscopy (SEM) micrographs show hybrid CNC bonded CNTs are homogeneously dispersed on the carbon fiber surface. According to the in-situ bending test under the optical microscope, crack propagation is hindered by engineered hybrid CNT nanostructures in the modified CFRP whereas neat CFRP exhibits low crack growth resistance due to the uninterrupted crack propagation in the continuous epoxy matrix. Our results imply that this strategy probes the importance of new controlled manufacturing of hybrid nanostructures through evaporation‑induced self‑assembly of nanocolloidal droplets, and allows for tailoring of the desired properties of nanostructured composites. 

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4. Composite Recycling with Biocatalytic Thermoset Reforming

   https://doi.org/10.1021/jacs.4c10838  

   Olivar, Clarissa; Yu, Zehan; Miller, Ben; Tangalos, Maria; Jenkinson, Cory B; Nutt, Steven R; Oakley, Berl R; Wang, Clay_C C; Williams, Travis J (November 2024, Journal of the American Chemical Society)

   Carbon fiber reinforced polymers (CFRPs, or composites) are increasingly replacing traditional manufacturing materials used in the automobile, aerospace, and energy sectors. With this shift, it is vital to develop end-of-life processes for CFRPs that retain the value of both the carbon fibers and the polymer matrix. Here we demonstrate a strategy to upcycle pre- and post-con- sumer polystyrene-containing CFRPs, crosslinked with unsaturated polyesters or vinyl esters, to benzoic acid. The thermoset matrix is upgraded via biocatalysis utilizing an engineered strain of the filamentous fungus Aspergillus nidulans, which gives access to valuable secondary metabolites in high yields, exemplified here by (2Z,4Z,6E)-octa-2,4,6-trienoic acid. Reactions are engineered to preserve the carbon fibers, with much of their sizing, so that the isolated carbon fiber plies are manufactured into new composite coupons that exhibit mechanical properties comparable to virgin manufacturing substrates. In sum, this represents the first system to reclaim high value from both the fiber fabric and polymer matrix of a CFRP. 

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5. EFFECTS OF CARBON NANOFIBER Z-THREADS ON THE LONGITUDINAL COMPRESSIVE STRENGTH OF UNIDIRECTIONAL CFRP LAMINATES

   Kirmse, Sebastian; Kim, Keonhyeong; Ranabhat, Bikash; Hsiao, Kuang-Ting (May 2019, SAMPE 2019 Proceedings, May 20-23, Charlotte, NC.)

   In this study, unidirectional carbon fiber prepregs that contain long carbon nanofiber (CNF) z threads as a through-thickness (z-directional) reinforcement were manufactured. The CNF z threads are long enough to thread through multiple carbon fiber (CF) arrays, which creates a multi-scale CNF/CF/resin-composite. The CNF z-threaded prepregs were manufactured using an electric-field aligned flow-transferring process. It was hypothesized that the CNF z-threads with the zig-zag threading pattern reinforces the interlaminar and intralaminar regions of the CFRP laminate thus improve the compressive strength by reducing the chance of carbon fiber buckling. Compressive testing was performed per modified version of ASTM D695 (i.e., SACMA SRM 1R 94) to evaluate the compressive strength of the CNF z-threaded CFRP (ZT-CFRP) laminates. The samples were manufactured using AS4 carbon fibers, EPON 862/Epikure-W resin and a 1wt% CNF content. ZT-CFRP testing results were compared with unaligned CNF-modified CFRP (UA-CFRP) and unmodified CFRP samples to investigate the impact of the CNF z-threads on the compressive strength. Results showed an increase of ~15% for the compressive strength of ZT CFRPs, whereas the UA-CFRPs experienced a decrease of ~8% when compared to unmodified CFRPs. It was concluded that CNF/carbon fiber interlocking stops and delays crack growth, and helps to stabilize carbon fibers from further buckling. 

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