Search for: All records

The interface characteristics of the matrix and fibers significantly influence the evolution of residual stress in composite materials. In this study, we provide a methodology for reducing the residual stress in laminated composites by modifying the thermomechanical properties at the fiber–matrix interface. A hydrothermal chemical growth method was used to grow Zinc Oxide nanowires on the carbon fibers. We then utilized a novel digital image correlation approach to evaluate strains and residual stresses, in situ, throughout the autoclave curing of composites. We find that interface modification results in the reduction of residual stress and an increase in laminate strength and stiffness. Upon growing ZnO NWs on the carbon fibers, the maximum in situ in-plane strain components were reduced by approximately 55% and 31%, respectively, while the corresponding maximum residual stresses were decreased by 50.8% and 49.33% for the cross-play laminate [0°/90°] layup in the x and y directions, respectively. For the [45°/-45°] angle ply layup in the x-direction, the strain was decreased by 27.3%, and the maximum residual stress was reduced by 41.5%, whereas in the y-direction, the strain was decreased by 166.3%, and the maximum residual stress was reduced by 17.8%. Furthermore, mechanical testing revealed that the tensile strength for the [45°/-45°] and [0°/90°] laminates increased by 130% and 20%, respectively, with the interface modification. 

Additively manufactured (AM) composites based on short carbon fibers possess strength and stiffness far less than their continuous fiber counterparts due to the fiber’s small aspect ratio and inadequate interfaces with the epoxy matrix. This investigation presents a route for preparing hybrid reinforcements for AM that comprise short carbon fibers and nickel-based metal-organic frameworks (Ni-MOFs). The porous MOFs furnish the fibers with tremendous surface area. Additionally, the MOFs growth process is non-destructive to the fibers and easily scalable. This investigation also demonstrates the viability of using Ni-based MOFs as a catalyst for growing multi-walled carbon nanotubes (MWCNTs) on carbon fibers. The changes to the fiber were examined via electron microscopy, X-ray scattering techniques, and Fourier-transform infrared spectroscopy (FTIR). The thermal stabilities were probed by thermogravimetric analysis (TGA). Tensile and dynamic mechanical analysis (DMA) tests were utilized to explore the effect of MOFs on the mechanical properties of 3D-printed composites. Composites with MOFs exhibited improvements in stiffness and strength by 30.2% and 19.0%, respectively. The MOFs enhanced the damping parameter by 700%. 

Residual stresses are detrimental to composite structures as they induce processing defects like debonding, delamination, and matrix cracking which significantly decrease their load-bearing capability. In this research, a new in-situ approach using digital image correlation is utilized to analyze the effect of the cure cycle modification on residual stress evolution during processing. It was found that the modified cure cycle comprising abrupt cooling after gelation reduces the residual stresses. Five different layup configurations are investigated to examine the effect of fiber direction. A maximum average residual stress reduction of 31.8% is observed for the balanced unsymmetric [30/-30/60/-60] laminate. The residual stress reduction results in an increase in failure strength between 4 and 12% in the different layups and can lead up to a 22% increase in first-ply failure strength. 

Thin-ply composite laminates are of interest for several applications in aerospace and other high-performance industries due to their ability to delay transverse microcracking and delamination in static, fatigue, and impact loadings. It is essential to understand the evolution of thermal residual stresses during cure to optimize the manufacturing process of thin-ply composites for deep-space applications. In this research, processing induced residual stresses in thin-ply laminates are evaluated by devising a novel in-situ experimental approach. Thin-ply prepreg laminates are cured in a specially designed autoclave with viewports with plies laid upon a flat tool and a curved tool. The curved tool configuration used in this research is designed to simulate cryogenic fuel tank surfaces. The evolution of residual stresses in terms of out-of-plane displacement is characterized using Digital Image Correlation (DIC) during the autoclave cure cycle. 

Cure shrinkage of the polymer matrix during the composite manufacturing process leads to residual stresses, which can adversely affect the structural integrity and dimensional stability of composite structures. In this paper, a novel approach is developed for measuring the resin shrinkage and strain evolution of an epoxy resin (EPON-862) in the composite manufacturing environment. The resin is cured in a custom-designed autoclave with borosilicate viewports, while digital image correlation (DIC) is used to analyze the strain evolution throughout the cure cycle. These processing induced strains are correlated to the cure-state using differential scanning calorimetery (DSC). The different mechanisms involved in the polymer strain evolution during composite processing are discussed. 

In this investigation, multi-walled carbon nanotubes (MWCNTs) were grown over carbon fiber fabrics via a relatively nondestructive synthesis technique. The MWCNTs patches were grown into three different topologies: uniform, fine patterned and coarse patterned. Hybrid carbon fiber-reinforced polymer composites (CFRPs) were fabricated based on the patterned reinforcements. Tensile tests, dynamic mechanical thermal analyses (DMTA) and flexure load relaxation tests were carried out to investigate the effect of the patterned nano-reinforcement on the static, dynamic, glass transition, and viscoelastic performance of the hybrid composites. Results revealed that the hybrid composite based on fine-patterned topology achieved better performance over all other configurations as it exhibited about 19% improvement in both the strength and modulus over the reference composite with no MWCNTs. Additionally, the increase in glass transition for this composite was as high as 13%. The damping parameter (tan δ) was improved by 46%. The stress relaxation results underlined the importance of patterned MWCNTs in minimizing the stress decay at elevated temperatures and loading conditions. Utilizing patterned MWCNTs topology significantly reduced the stress decay percentage at the thermomechanical conditions 60 MPa and 75 °C from 16.7% to 7.8%. These improvements are attributed to both the enhanced adhesion and large interface area by placing MWCNTs and by inducing an interlocking mechanism that allows the interaction of the three constituents in load transfer, crack deflection and hindering undesired viscoelastic deformations under different thermomechanical loadings.