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1. Effects of debulking on the fiber microstructure and void distribution in carbon fiber reinforced plastics

   https://doi.org/10.1016/j.compositesa.2022.107364  

   Schey, Mathew; Beke, Tibor; Owens, Kyle; George, Andy; Pineda, Evan; Stapleton, Scott (February 2023, Composites Part A: Applied Science and Manufacturing)

   Carbon Fiber Reinforced Plastics (CFRPs) are widely used due to their high stiffness to weight ratios. A common process manufacturers use to increase the strength to weight ratio is debulking. Debulking is the process of compacting a dry fibrous reinforcement prior to resin infusion. This process is meant to decrease the average inter-fiber distance, effectively increasing the fiber volume fraction of the sample. While this process is widely understood macroscopically its effects on fibrous microstructures have not yet been well characterized. The aim of this work is to compare the microstructures of three CFRP laminates, varying only the debulking step in the manufacturing process. High resolution serial sections of all three laminates were taken for analysis. Using these scans, the fiber positions were reconstructed. Statistical descriptors such as local fiber and void volume fractions, fiber orientation, and void distribution and morphology were then generated for each sample. Fiber clusters present within the material were identified and analyzed for each level of debulking applied. Using these descriptors, the effects of debulking on the morphology and organization of the composite microstructure was evaluated. 

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2. 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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3. ANALYTICAL MODEL FOR COMPOSITE TRANSVERSE STRENGTH BASED ON COMPUTATIONAL MICROMECHANICS

   https://doi.org/10.1615/IntJMultCompEng.2023048428  

   Shah, Sagar P.; Maiarù, Marianna (January 2023, International Journal for Multiscale Computational Engineering)

   The transverse strength of fiber-reinforced composites is a matrix-dominated property whose accurate prediction iscrucial to designing and optimizing efficient, lightweight structures. State-of-the-art analytical models for compositestrength predictions do not account for fiber distribution, orientation, and curing-induced residual stress that greatlyinfluence damage initiation and failure propagation at the microscale. This work presents a novel methodology to develop an analytical solution for transverse composite strength based on computational micromechanics that enables the modeling of stress concentration due to representative volume elements (RVE) morphology and residual stress. Finiteelement simulations are used to model statistical samples of composite microstructures, generate stress-strain curves,and correlate statistical descriptors of the microscale to stress concentration factors to predict transverse strength as a function of fiber volume fraction. Tensile tests of thin plies validated this approach for carbon- and glass-reinforced composites showing promise to obtain a generalized analytical model for transverse composite strength prediction. 

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4. Effect of Process Parameters on Void Distribution, Volume Fraction, and Sphericity within the Bead Microstructure of Large-Area Additive Manufacturing Polymer Composites

   https://doi.org/10.3390/polym14235107  

   Sayah, Neshat; Smith, Douglas E. (December 2022, Polymers)

   Short carbon fiber-reinforced composite materials produced by large-area additive manufacturing (LAAM) are attractive due to their lightweight, favorable mechanical properties, multifunctional applications, and low manufacturing costs. However, the physical and mechanical properties of short carbon-fiber-reinforced composites 3D printed via LAAM systems remain below expectations due in part to the void formation within the bead microstructure. This study aimed to assess void characteristics including volume fraction and sphericity within the microstructure of 13 wt% short carbon fiber acrylonitrile butadiene styrene (SCF/ABS). Our study evaluated SCF/ABS as a pellet, a single freely extruded strand, a regularly deposited single bead, and a single bead manufactured with a roller during the printing process using a high-resolution 3D micro-computed tomography (µCT) system. Micro voids were shown to exist within the microstructure of the SCF/ABS pellet and tended to become more prevalent in a single freely extruded strand which showed the highest void volume fraction among all the samples studied. Results also showed that deposition on the print bed reduced the void volume fraction and applying a roller during the printing process caused a further reduction in the void volume fraction. This study also reports the void’s shape within the microstructure in terms of sphericity which indicated that SCF/ABS single freely extruded strands had the highest mean void sphericity (voids tend to be more spherical). Moreover, this study evaluated the effect of printing process parameters, including nozzle temperature, extrusion speed and nozzle height above the printing table on the void volume fraction and sphericity within the microstructure of regularly deposited single beads. 

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5. Computational homogenization of linear elastic properties in porous non-woven fibrous materials

   https://doi.org/10.1016/j.mechmat.2023.104868  

   Kuts, Mikhail; Walker, James; Newell, Pania (February 2024, Mechanics of Materials)

   Graham-Brady, Lori (Ed.)

   Porous non-woven fibrous media are widely used in various industrial applications such as filtration, insulation, and medical textiles due to their unique structural and functional properties. However, predicting the mechanical behavior of these materials is challenging due to their complex microstructure and anisotropic nature. In this study, a computational model is developed to simulate the mechanical response of porous non-woven fibrous media under external loading. The model is based on the finite element method and takes into account the geometric and material properties of the fibers and the void spaces between them. The effects of various factors such as fiber size, porosity, and fibers’ intersection ratio on the mechanical behavior of the material are investigated. The results reveal that the material’s porosity and fibers’ intersection ratio are the most significant factors influencing its mechanical properties. Additionally, the increase in fiber diameter has a relatively minor effect on the material’s elastic properties. However, such changes in elastic properties are primarily attributed to the increase in randomness within the fibrous network, which is directly related to the fiber diameter for the investigated structure. The proposed computational model predicts the mechanical properties of porous non-woven fibrous media and can provide invaluable insights into the design and optimization of porous non-woven fibrous media for various scientific and engineering applications. 

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