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Strong, tough, and lightweight composites are increasingly needed for diverse applications, from wind turbines to cars and aircraft. These composites typically contain sheets of strong and high-modulus fibers in a matrix that are joined with other materials to resist fracture. Coupling these dissimilar materials together is challenging to enhance delamination properties at their interface. We herein investigate using a trace amount of carbon nanotube sheets to improve the coupling between composite skins and core in a composite sandwich. Ultra-thin (~100 nm) forest-drawn multi-walled carbon nanotube (MWNT) sheets are interleaved within the skin/core interphase, with MWNTs aligned in the longitudinal direction. The mechanical behavior is characterized by end notched flexural testing (ENF). With two MWNT sheets placed in the skin/core interphase, the following performance enhancements are achieved: 36.8 % increase in flexural strength; 127.3 % and 125.7 % increases in mode I & II fracture toughness values, respectively; and 152.8 % increase in interfacial shear strength (IFSS). These are achieved with negligible weight gain of the composite sandwich (0.084 wt% increase over the baseline sandwich without MWNT sheets). The finite element simulation results show that MWNT sheets enhance the skin/core coupling by reducing stress concentration, enabling the transition from catastrophic brittle failure to a stable ductile failure mode. The MWNT sheets interleaved sandwich composites are thus demonstrated to be stronger and tougher while providing electrical conductivity (4.3 × 104 S/m) at the skin/core interface for potential de-icing, electromagnetic interference shielding, and structural health monitoring. 

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. 

The objective of this paper is to predict the fiber/matrix interfacial debond strength in composites. Atomic force microscopy (AFM) images of the surface topography of a de-sized carbon fiber reveal that there are surface asperities present at various length scales ranging from a nanometer to several microns. These asperities are likely caused by shrinkage of the polyacrylonitrile (PAN) precursor during the graphitization process. In order to bridge the length scales, a Fourier series-decomposition covering a range of asperity wavelengths and amplitudes is necessary to effectively capture the roughness of the fiber surface at different length scales. Further, once a surface asperity profile has been resolved into individual subcomponents using Fourier-decomposition, MD simulations can then be employed to obtain the interfacial shear strength of the subcomponent asperity of a given amplitude and wavelength. Finally, by recombining the peak interfacial shear force obtained from each of these subcomponents into the overall shear force for the fiber surface profile, the length-scale -averaged shear strength can be obtained for any given asperity. The objective of this paper is to use this novel approach to determine the interfacial shear strength of de-sized carbon fiber embedded in an epoxy matrix and compare predicted results with experimental data. 

Polymer matrix composites have high strengths in tension. However, their compressive strengths are much lower than their tensile strengths due to their weak fiber/matrix interfacial shear strengths. We recently developed a new approach to fabricate composites by overwrapping individual carbon fibers or fiber tows with a carbon nanotube sheet and subsequently impregnate them into a matrix to enhance the interfacial shear strengths without degrading the tensile strengths of the carbon fibers. In this study, a theoretical analysis is conducted to identify the appropriate thickness of the nanocomposite interphase region formed by carbon nanotubes embedded in a matrix. Fibers are modeled as an anisotropic elastic material, and the nanocomposite interphase region and the matrix are considered as isotropic. A microbuckling problem is solved for the unidirectional composite under compression. The analytical solution is compared with finite element simulations for verification. It is determined that the critical load at the onset of buckling is lower in an anisotropic carbon fiber composite than in an isotropic fibfer composite due to lower transverse properties in the fibers. An optimal thickness for nanocomposite interphase region is determined, and this finding provides a guidance for the manufacture of composites using aligned carbon nanotubes as fillers in the nanocomposite interphase region.