An official website of the United States government
Abstract The current study confirms that modified carbon fiber reinforced polymer (CFRP) composites have higher fracture toughness than unmodified CFRP composites achieved by exploiting the synergistic effect of a polycarbonate (PC)/acrylonitrile butadiene styrene (ABS) blend in toughening the diglycidyl ether of bisphenol A (DGEBA) epoxy resin. The CFRP composite specimens are tested at near cryogenic temperatures using TMA, DMA, and microcrack analysis to determine the best‐suited concentration of ABS in the PC/ABS blend. TMA and DMA results, as well as microcrack analysis at cryogenic temperatures (CT), confirm that the blend 90/10 is effective in reducing the brittle nature of DGEBA resin and increasing bond strength, resulting in the fracture toughness enhancement of CFRP specimens at CT. Further investigation of 90/10 modified CFRP (90/10 m‐CFRP) and unmodified CFRP specimens using Mode II fracture using ENF test and SEM analysis reveal significant reduction in brittle characteristics of matrix with increase in elongation at failure and fracture surface morphologies confirm nano web‐like structures bridging the CF layers, proving to improve fiber/matrix bond strength. This study concludes the effectiveness of hybrid PC/ABS blend in synergistically‐modifying DGEBA resin for improved fracture toughness of CFRP laminates across a wide temperature range (−150°C to 150°C).
more »
« less
Thermal Synergistic Effect on CFRP Laminates with Modified Fiber/Matrix Systems for Heat Transfer Applications
Abstract Carbon fiber reinforced polymer (CFRP) laminates are modified to enhance their suitability for various thermal applications. A synergistic approach utilizing the effect of various conductive and insulative modifiers with diglycidyl ethers of bisphenol A (DGEBA) epoxy resin and/carbon fiber (CF) is explored. In CFRP laminates developed after modifications made in epoxy resin using a thermoplastic material, such as polycarbonate (PC) and/or acrylonitrile butadiene styrene (ABS), exhibit high thermal resistance (TR) of 77.1% compared to unmodified CFRP. In contrast, modifications made using conductive mediums like phosphonium (P), imidazolium (I), or silanized‐graphene oxide (SGO) have lower TR of 25.7%, 30.5%, and 32.4%, respectively. A temperature gradient (TG) enhancement of 75% is reported for the 1.5 wt% PC/ABS modified CFRP laminates. On the contrary, modifications using 0.5 parts per hundred (phr)P, 0.5 phr I, and 1 g L−1SGO in epoxy reduce the TG by 25%, 30%, and 32%, respectively. Thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC) analyses are done to explore the thermal characteristics of each case of modification. Finally, scanning electron microscopy images confirm the distribution profile of the modifiers used. Based on the types of modifications performed, the current study can offer insightful information on the thermal performances of modified CFRP laminates.
more »
« less
- Award ID(s):
- 1719875
- PAR ID:
- 10548205
- Publisher / Repository:
- Wiley Online Library
- Date Published:
- Journal Name:
- Macromolecular Chemistry and Physics
- Volume:
- 224
- Issue:
- 11
- ISSN:
- 1022-1352
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
More Like this
-
-
Previous studies have provided evidence that reinforcement of epoxy adhesives with nanostructures such as carbon nanofibers (CNFs) produces higher strength bonded joints between carbon fiber reinforced polymer (CFRP) laminates and shifts bond-line failure modes from the adhesive into the laminate. Despite this, there has been no research dedicated to applying reinforced adhesives to the bonding of nano-reinforced CFRP such as CNF z-threaded carbon fiber reinforced polymer (ZT-CFRP) laminates, which have been proven to exhibit increased interlaminar shear strength, mode-I delamination toughness, and compressive strength over traditional CFRP. This study examined the effectiveness of using CNF reinforced epoxy adhesives for unidirectional ZT-CFRP laminate bonding through single-lap shear tests using the ASTM D5868-01 standard. Unidirectional CFRP laminate samples bonded with both epoxy adhesive and CNF reinforced epoxy adhesive were also tested for comparison. It was found that the average shear strength observed for ZT-CFRP samples bonded with CNF reinforced epoxy adhesive was approximately 44% and 26 % higher than that of CFRP samples bonded with epoxy adhesive and CNF reinforced epoxy adhesive, respectively. Microscopic image analysis was performed to examine the mode of bond failure. The roles of nanomaterials in the fracture mechanism of the adhesives and the composite laminates are also discussed.more » « less
-
Carbon fiber reinforced polymer (CFRP) composites have been increasingly used to replace metal parts in many industries such as aerospace, marine, automotive, and sporting goods. The CFRP parts compared with their metallic counter parts have the advantages of lightweight, significantly higher tensile strength, stiffer, and corrosion resistant. On the other hand, compared with many metal parts, the CFRP parts have many well-known disadvantages including the lower toughness, lower through-thickness tensile and shear strengths, lower thermal conductivity, lower electrical conductivity, and lower operating temperature. These disadvantages have made the conversion from metal parts into CFRP parts challenging and costly to design, manufacture, and maintain. The use of nanoparticles in polymer has been studied in the recent two decades. Carbon nanotubes (CNTs) and carbon nanofibers (CNFs) have been dispersed in various thermoset and thermoplastic polymers and improved the mechanical, electrical, and thermal properties; however, the properties were not comparable to CFRP. Later, researchers tried to infuse CNTs or CNFs into either carbon fiber preforms [1] or glass fiber preforms [2] for improving the mechanical properties. But the results were marginal and with great uncertainty due to the challenges of nanoparticle dispersion, filtering, and alignment while being infused through the fiber preform. The glass fiber preform experiments ended with relatively more consistent improvement than the carbon fiber preform experiments since that the glass fiber preform has significantly larger pores than the carbon fiber preform' s. The small pore size presented a great challenge for infusing millions of unaligned long CNTs or CNFs through the carbon fiber preform without being filtered. To infuse long CNFs or CNTs through the carbon fiber preform and achieve reliable improvements, especially for 55% or higher carbon fiber volume fraction with increasingly tighter pores, an innovative plan for the processing and nano-reinforcing strategy is necessary. The z-threading strategy [3, 4, 5] has been reported to have consistent experimental successes in achieving the statistically meaningful improvement in multifunctional properties. The manufacturing steps of the CNF z-threaded CFRP (ZT-CFRP) are: (1) disperse the CNFs in a resin, (2) use a strong electrical field to align the CNFs in either the B-stage epoxy film or a CNF/resin impregnated sponge layer, whereas the CNFs are aligned in the through-thickness direction of the film or sponge layer. (3) place the resin film or sponge layer on a preheated dry carbon fiber fabric and press the resin film into the hot carbon fabric and allow the resin flow to carry the well-aligned CNFs to thread through the pores in the carbon fabric. (4) cool down the resin saturated and CNF z-threaded carbon fiber fabric to obtain the ZT-CFRP prepreg. (5) use the ZT-CFRP prepreg to make the ZT-CFRP laminate. Compared with the traditional CFRP, the ZT-CFRP laminates were reported of having improvement in the Mode-I delamination toughness, interlaminar shear strength, longitudinal compressive strength, through-thickness electrical conductivity, through-thickness thermal conductivity, and can reach the carbon fiber volume fraction of 55-80%. It is an effective approach to achieve a multifunctional CFRP for potentially expanding CFRP's applications.more » « less
-
Carbon fiber reinforced polymer (CFRP) composites have been increasingly used in many vehicles such as airplanes, automobiles, and ships due to the advantages of high-strength, high-modulus, lightweight, and corrosion resistance. CFRP structures enhance the vehicle's performance, energy-efficiency, comfort, and safety. However, a common safety concern is how the CFRP materials perform when the vehicle is in fire and if there are enough time to safely evacuate the passengers. The elevated temperature can soften and decompose the polymer matrix, delaminate the CFRP laminate, and burn the CFRP through the contact with oxygen. As a result, the thermal and flammability response of CFRP is important for considering CFRP for vehicle applications; and some specialty high-temperature or flame/smoke/toxicity-proven resins have been investigated for CFRP parts manufacturing due to the needs. In this paper, a novel flame resistant hypothesis of utilizing the unique nano/micro- interlocked fiber reinforcing structure of the long-range carbon nanofiber z-threaded CFRP (ZT-CFRP) composite laminates for improving the flammability performance will be investigated. The carbon nanofibers (CNT) and carbon nanotubes (CNT), which have excellent thermal and mechanical properties, will be dispersed in an epoxy resin and will zig-zag thread through a carbon fiber fabric using an electrical/flow assisted impregnation process to create the unidirectional ZT-CFRP prepregs, respectively, which will be further processed into ZT-CFRP composite laminates. The UL-94 flammability test will be employed to characterize the ZT-CFRP laminates' flammability performance against the control baseline data of the regular CFRP, all without using any flame retardant chemicals. An impressive self-extinguishing flammability characteristic of the CNF based ZT-CFRP samples has been distinctly identified from all the samples. The UL-94 testing results and the effectiveness of using the long-range nanofiber z-threading strategy for enabling the novel nano/microstructure-induced flame resistant and self-extinguishing characteristics will be discussed.more » « less
-
The matrix sensitive weaknesses of Carbon Fiber Reinforced Polymer (CFRP) laminates are usually magnified by mainstream additive manufacturing (AM) methods due to the AM-process-induced voids and defects. In this paper, a novel Magnetic Compaction Force Assisted-Additive Manufacturing (MCFA-AM) method is used to print Carbon Nanofibers (CNF) Z-threaded CFRP (i.e., ZT-CFRP) composite laminates. The MCFA-AM method utilizes a magnetic force to simultaneously support, deposit, and compact Continuous Carbon Fiber Reinforced Polymer (C-CFRP) composites in free space and quickly solidifies the CFRP part without any mold; it effectively reduces the voids. Past research proved that the zig-zag threading pattern of the CNF z-threads reinforces the interlaminar and intralaminar regions in the ZT-CFRP laminates manufactured by the traditional Out of Autoclave-Vacuum Bag Only (OOA-VBO) method, and enhances the matrix sensitive mechanical, thermal, and electrical properties. In this study, the longitudinal compressive test (ASTM D695, i.e., SACMA SRM 1R-94) was performed on the MCFA-AM printed ZT-CFRP laminate. The results were compared with unaligned CNF-modified CFRP (UA-CFRP), control CFRP, and no-pressure CFRP samples’ data to investigate the impact of the CNF z-threads and MCFA-AM process on the CFRP’s performance. The 0.5-bar MCFA-AM printed ZT-CFRP showed comparable longitudinal compressive strength with the 1-bar OOA-VBO cured CFRP.more » « less
- Free Publicly Accessible Full Text
-
Accepted Manuscript1.0
- Journal Article:
- https://doi.org/10.1002/macp.202200462
