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.
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This content will become publicly available on June 1, 2025
Enhancing the interlaminar adhesion of carbon fiber composites via carbon nanotube sheets
Spread tow carbon fiber composites are receiving increased attention for diverse applications in space and sports gear due to their thin form, which is suitable for deployable structures, and high tensile strength. Their compressive strength, however, is much lower than their tensile strength due to low interlaminar strength. Herein we report a facile technique to enhance their performance through interlaminar insertion of aligned carbon nanotube (CNT) sheets. The inserted CNT sheets also provide electrical conductivity in the composites even at a low CNT loading below the electrical percolation threshold established for CNT-filled composites. Mechanical and electrical characterization was conducted on the CNT sheet-inserted composites and the baseline composites. Results show that the CNT sheets increase the compressive strength by 14.7% compared with the baseline. Such an increase is attributed to the increased adhesion provided by the inserted CNT sheets at the interface between neighboring plies, which also increases the interlaminar shear strength by 33.0% and the interfacial mode-II fracture toughness by 34.6% compared with the baseline composites without inserting CNT sheets. The well-aligned CNT sheet structure maintained between the neighboring plies contributed to a 64.7% increase in electrical conductivity compared with the baseline composites. The findings indicate that the insertion of well-aligned ultrathin CNT sheets in the interlaminar region of a spread tow carbon fiber composite provides significant enhancement in mechanical and electrical performance, paving the path toward applications where both mechanical and electrical performances are crucial, such as for structural health monitoring, lightning protection, and de-icing in aircraft and wind blades.
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- Award ID(s):
- 2219347
- PAR ID:
- 10553074
- Publisher / Repository:
- www.academia.edu
- Date Published:
- Journal Name:
- Academia Materials Science
- Volume:
- 1
- Issue:
- 2
- ISSN:
- 2997-2027
- Subject(s) / Keyword(s):
- spread tow carbon fiber, compressive strength, interlaminar shear strength (ILSS), mode-II fracture toughness, fractographic analysis
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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