The Mechanical Properties of Fiber Metal Laminates Based on 3D Printed Composites

The production and mechanical properties of fiber metal laminates (FMLs) based on 3D printed composites have been investigated in this study. FMLs are structures constituting an alternating arrangement of metal and composite materials that are used in the aerospace sector due to their unique mechanical performance. 3D printing technology in FMLs could allow the production of structures with customized configuration and performance. A series of continuous carbon fiber reinforced composites were printed on a Markforged system and placed between layers of aluminum alloy to manufacture a novel breed of FMLs in this study. These laminates were subjected to tensile, low velocity and high velocity impact tests. The results show that the tensile strength of the FMLs falls between the strength of their constituent materials, while the low and high velocity impact performance of the FMLs is superior to those observed for the plain aluminum and the composite material. This mechanism is related to the energy absorption process displayed by the plastic deformation, and interfacial delamination within the laminates. The present work expects to provide an initial research platform for considering 3D printing in the manufacturing process of hybrid laminates.     

The Synergistic Effect of Temperature and Loading Rate on Deformation for Thermoplastic Fiber Metal Laminates

The glass fiber reinforced polypropylene/AA2024 hybrid laminates (short for Al/Gf/PP laminates) as structural materials were prepared and formed by hot pressing. The synergistic effects of temperature and loading speed on the laminate deformation under tensile and bending conditions were investigated and analyzed in this study. In tension, stress–strain curves presented bimodal types effected by tensile rates and temperatures. The state of PP resin determines the mechanical behavior of the FMLs. The tensile rate has no effect on FML deformation without heating or over the melting point of PP resin (about 170 °C). The softening point of PP resin (about 100 °C) is characteristic temperature. When the temperature exceeds the softening point but does not reach the melting point, the tensile strength and elongation will demonstrate coordinated growth at a relatively high tensile speed. The efficiency of fiber bridging is affected significantly since the resin is the medium that transfers load from the metal to the fiber. Under bending, the curves presented a waterfall decrement with temperature increment. The softening point of resin matrix is the key in a bending process. When the temperature is near the softening point, deformation is sensitive to both the temperature and the loading speed to a certain extent. If temperature is lower than softening point, deformation is mainly guided by temperature. If the temperature is beyond the softening point, loading speed is in a leading position of deformation. The bending strength gradually increases with loading rate. By using these deformation characteristics, the deformation of the thermoplastic laminates can be controlled in stamping or other plastic forming processes for thermoplastic fiber metal laminates.     

Cyclic Relaxation,Impact Properties and Fracture Toughness of Carbon and Glass Fiber Reinforced Composite Laminates

In this paper, the mechanical properties of fiber-reinforced epoxy laminates are experimentally tested. The relaxation behavior of carbon and glass fiber composite laminates is investigated at room temperature. In addition, the impact strength under drop-weight loading is measured. The hand lay-up technique is used to fabricate composite laminates with woven 8-ply carbon and glass fiber reinforced epoxy. Tensile tests, cyclic relaxation tests and drop weight impacts are carried out on the carbon and glass fiber-reinforced epoxy laminates. The surface release energy G_IC and the related fracture toughness K_IC are important characteristic properties and are therefore measured experimentally using a standard test on centre-cracked specimens. The results show that carbon fiber-reinforced epoxy laminates with high tensile strength give high cyclic relaxation performance, better than the specimens with glass fiber composite laminates. This is due to the higher strength and stiffness of carbon fiber-reinforced epoxy with 600 MPa compared to glass fiber-reinforced epoxy with 200 MPa. While glass fibers show better impact behavior than carbon fibers at impact energies between 1.9 and 2.7 J, this is due to the large amount of epoxy resin in the case of glass fiber composite laminates, while the impact behavior is different at impact energies between 2.7 and 3.4 J. The fracture toughness K_IC is measured to be 192 and 31 MPa √m and the surface energy G_IC is measured to be 540.6 and 31.1 kJ/m² for carbon and glass fiber-reinforced epoxy laminates, respectively.     

A Study on Tensile Behavior According to the Design Method for the CFRP/GFRP Grid for Reinforced Concrete

In the present study, fiber-reinforced plastics (FRP) grid-reinforced concrete with very rapid hardening polymer (VRHP) mortar composites were fabricated using three types of design methods for the FRP grid (hand lay-up method, resin infusion method, and prepreg oven vacuum bagging method), along with two types of fibers (carbon fiber and glass fiber) and two types of sheets (fabric and prepreg). The FRP grid was prepared by cutting the FRP laminates into a 10 mm thick, 50 mm × 50 mm grid. The tensile behavior of the FRP grid embedded in composites was systematically analyzed in terms of the load extension, fracture mode, partial tensile strain, and load-bearing rate. The CFRP grid manufactured by the prepreg OVB method showed the best tensile behavior compared to the CFRP grid manufactured by the hand lay-up and resin infusion methods. The load-bearing of each grid point was proportional to the height from the load-bearing part when reaching the maximum tensile load. In addition, finite element analysis was conducted to compare the experimental and analysis results.     

The Curing Kinetics of E-Glass Fiber/Epoxy Resin Prepreg and the Bending Properties of Its Products

The curing kinetics can influence the final macroscopic properties, particularly the three-point bending of the fiber-reinforced composite materials. In this research, the curing kinetics of commercially available glass fiber/epoxy resin prepregs were studied by non-isothermal differential scanning calorimetry (DSC). The curing kinetic parameters were obtained by fitting and the apparent activation energy E_a of the prepreg, the pre-exponent factor, and the reaction order value obtained. A phenomenological nth-order curing reaction kinetic model was established according to Kissinger equation and Crane equation. Furthermore, the optimal curing temperature of the prepregs was obtained by the T-β extrapolation method. A vacuum hot pressing technique was applied to prepare composite laminates. The pre-curing, curing, and post-curing temperatures were 116, 130, and 153 °C respectively. In addition, three-point bending was used to test the specimens’ fracture behavior, and the surface morphology was analyzed. The results show that the differences in the mechanical properties of the samples are relatively small, indicating that the process settings are reasonable.     

A Study on the In-Plane Shear-after-Impact Properties of CFRP Composite Laminates

Impact loading on carbon fiber reinforced polymer matrix (CFRP) composite laminates can result in a significant reduction in their residual properties, and the (ShAI) properties of the composite material are essential to obtain the material allowable values of the shear dominated composite structures. In order to obtain the ShAI properties of the composite material in pure shear stress at a coupon level, this study presents theoretical, experimental, and numerical methods and analysis work on the in-plane shear and ShAI properties of the composite laminates. Theoretically, a method of sizing the composite specimen loading in shear is developed through comparing the load values due to buckling and the material failure. Following this, both impact tests using the drop-weight method and ShAI tests using the picture frame test method are conducted, and the influences of the impact energies on the impact damage and the residual ShAI values are evaluated. Moreover, a progressive failure finite element model based on the Hashin’s failure criterion and the cohesive zone model is developed, and a two-step dynamic analysis method is performed to simulate the failure process of the composite laminates under impact loading and ShAI loading. It is found that the impact damage with the cut-off energy, 50 J, causes a 26.8% reduction in the residual strength and the residual effective shear failure strain is about 0.0132. The primary reason of the shear failure is the propagation of both the matrix tensile failure and interlaminar delamination. It can be concluded that the proposed theoretical, experimental, and numerical methods are promising factors to study the ShAI properties of the composite materials.     

Hybrid Prepreg Tapes for Composite Manufacturing: A Case Study

The aim of this research was the preparation and characterization of hybrid prepreg tapes from glass multifilament roving (circular cross-section). The fiber, roving, and tape strength distribution was characterized by exploratory data analysis tools (especially quantile-quantile plot) and modeled by the three parameters’ Weibull distribution. For estimation of Weibull model parameters, the noniterative technique based on the so-called Weibull moments was used. It was shown that the prepared hybrid prepreg tapes prepared by controlled mechanical spreading technology developed by the authors improved mechanical tensile properties and can be used for the preparation of composites of complicated forms by robotic winding.     

Influence of the Size of the Fiber Filler of Corn Stalks in the Polylactide Matrix Composite on the Mechanical and Thermomechanical Properties

This paper presents results of a study on the effect of filler size in the form of 15 wt% corn stalk (CS) fibers on the mechanical and thermomechanical properties of polylactide (PLA) matrix composites. In the test, polylactidic acid (PLA) is filled with four types of length of corn stalk fibers with a diameter of 1 mm, 1.6 mm, 2 mm and 4 mm. The composites were composed by single screw extrusion and then samples were prepared by injection molding. The mechanical properties of the composites were determined by static tensile test, static bending test and Charpy impact test while the thermo-mechanical properties were determined by dynamic mechanical thermal analysis (DMTA). The composite structures were also observed using X-ray microcomputed tomography and scanning electron microscopy. In the PLA/CS composites, as the filler fiber diameter increased, the degradation of mechanical properties relative to the matrix was observed including tensile strength (decrease 22.9–51.1%), bending strength (decrease 18.9–36.6%) and impact energy absorption (decrease 58.8–69.8%). On the basis of 3D images of the composite structures for the filler particles larger than 2 mm a weak dispersion with the filler was observed, which is reflected in a significant deterioration of the mechanical and thermomechanical properties of the composite. The best mechanical and thermomechanical properties were found in the composite with filler fiber of 1 mm diameter. Processing resulted in a more than 6-fold decrease in filler fiber length from 719 ± 190 µm, 893 ± 291 µm, 1073 ± 219 µm, and 1698 ± 636 µm for CS1, CS1.6, CS2, and CS4 fractions, respectively, to 104 ± 43 µm, 123 ± 60 µm, 173 ± 60 µm, and 227 ± 89 µm. The fabricated green composites with 1 to 2 mm corn stalk fiber filler are an alternative to traditional plastic based materials in some applications.     

Numerical and Experiment Studies of Different Path Planning Methods on Mechanical Properties of Composite Components

The purpose of this paper is to study the effects of different trajectory planning methods on the mechanical properties of components. The scope of the research includes finite element simulation calculation and experimental tests of the actual structure. The test shall be carried out in the whole load range until the failure of the structure occurs. Taking the composite conical shell as an example, a variable angle initial path generation method of the conical shell surface is proposed, and the parallel offset algorithms based on partition and the circumferential averaging are proposed to fill the surface. Then, finite element analysis is carried out for the paths that satisfy the manufacturability requirements, the analysis results show that the maximum deformation and maximum transverse as well as longitudinal stress of fiber of circumferential averaging variable angle path conical shell are reduced by 16.3%, 5.85%, and 19.76%, respectively, of that of the partition variable angle path. Finally, the strength analysis of conical shells manufactured by different trajectory design schemes is carried out through finite element analysis and actual failure tests. The finite element analysis results are in good agreement with the experimental results of the actual structure. The results show that the circumferential uniform variable angle has good quality, and it is proved that the path planning algorithm that coordinates path planning and defect suppression plays an important role in optimizing placement trajectory and improving mechanical properties of parts.     

GL Beams Reinforced with Plywood in the Outer Layer

Glulam beams are increasingly used in the construction industry because of their high strength and the possibility of using round timber with smaller cross-sections. The load-bearing capacity of beams is strongly related to the quality of the outer layers and, in the case of wood, especially the tension zones. For these reasons, this study decided to replace the outer lamella with tensile plywood. The produced beams were subjected to static bending strength and modulus of elasticity evaluation. It was shown that the best static bending strength values were obtained for beams containing plywood in the tension layer. However, the change in structure in the tension zone of beams made of glued laminated timber results not only in an increase in the load capacity of elements produced in this way but also in a decrease in the range/range of the obtained results of bending strength. This way of modifying the construction of glued laminated beams allows a more rational use of available pine timber.     

Damage Characterization of Carbon Fiber Composite Pressure Vessels Based on Modal Acoustic Emission

This study characterized the damage characteristics of carbon fiber composite pressure vessels by the modal acoustic emission (MAE) method. The study showed how to use the extracted damage modal features and established MAE parameters to determine the damage mode of composite pressure vessels. First, the A₀ and S₀ Lamb modes of the AE signal were split through mode separation, and the time window was selected to establish the MAE characteristic parameters. Subsequently, based on the MAE parameters and the damage mode characteristics established from single damage experiments, a damage mode discrimination method was established. A bending test of carbon fiber composite laminates proved that the modal separation method and the MAE parameters establishment are reasonable and effective. The results from the hydraulic test of the graded loading performed on 20 MPa carbon fiber composite pressure vessels showed the accuracy of the damage mode discrimination method, and the damage state of the pressure vessel could be analyzed using the fiber fracture damage threshold according to the MAE parameters.     

Effect of Carbon Nanotubes on the Mechanical,Crystallization, Electrical and Thermal Conductivity Properties of CNT/CCF/PEKK Composites

Carbon nanotube/continuous carbon fiber–reinforced poly(etherketoneketone) (CNT/CCF/PEKK) prepreg tapes were prepared by the wet powder impregnation method, and then the prepreg tapes were molded into laminates. The effects of carbon nanotubes on the mechanical properties, conductivity, thermal conductivity and crystallinity of the composites were studied by universal testing machine, thermal conductivity and resistivity tester, dynamic mechanical analyzer (DMA) and differential scanning calorimeter (DSC). The results show that when the content of carbon nanotubes is 0.5 wt% (relative to the mass of PEKK resin, the same below), the flexural strength and interlaminar shear strength of the laminates reach the maximum, which are increased by 15.99% and 18.16%, respectively, compared with the laminates without carbon nanotubes. The results of conductivity and thermal conductivity show that the higher the content of carbon nanotubes, the better the conductivity and thermal conductivity of the material. DSC results show that the addition of CNT promoted the crystallization of PEKK in the material and decreased the cold crystallization of PEKK. DMA results show that the deformation resistance of the material can be improved by adding an appropriate amount of CNT and the bonding between CF and PEKK can be enhanced, while excessive CNT destroys this phenomenon.     

A Systematic Characterization Approach for Vacuum Bag Only Prepregs towards an Accurate Process Design

Aerospace-grade composite parts can be manufactured using Vacuum Bag Only prepregs through an accurate process design. Quality in the desired part can be realized by following process modeling, process optimization, and validation, which strongly depend on a primary and systematic material characterization methodology of the prepreg system and material constitutive behavior. The present study introduces a systematic characterization approach of a Vacuum Bag Only prepreg by covering the relevant material properties in an integrated manner with the process mechanisms of fluid flow, consolidation, and heat transfer. The characterization recipe is practiced under the categories of (i) resin system, (ii) fiber architecture, and (iii) thermal behavior. First, empirical models are successively developed for the cure-kinetics, glass transition temperature, and viscosity for the resin system. Then, the fiber architecture of the uncured prepreg system is identified with X-ray tomography to obtain the air permeability. Finally, the thermal characteristics of the prepreg and its constituents are experimentally characterized by adopting a novel specimen preparation technique for the specific heat capacity and thermal conductivity. Thus, this systematic approach is designed to provide the material data to process modeling with the motivation of a robust and integrated Vacuum Bag Only process design.     

Dynamic Alloying of Steels in the Super-Deep Penetration Mode

The dynamic effects observed in collisions represent a specific area of high-energy interaction located at the boundary of mechanics, hydrodynamics, shock wave physics, and alternating high-pressure regions. The paper shows that in the volume of a solid metal body, as a result of dynamic alloying by a high-speed stream of powder particles in the super-deep penetration mode (SDP), fiber structures of altering material arise, forming the framework of the composite material. The stream of powder particles in the metal obstacle following the path of least resistance and the impact of shock waves on particles results in a volumetric framework from the products of interaction between the injected and matrix materials. When using SDP, defective structural elements (channeled)—germs of reinforcing fibers arise. At the subsequent heat treatment, there is an intensive diffusion. The growth process of reinforcing fibers shifts to higher temperatures (as compared to the standard mode), leading to an increase in the bending strength of the fiber material up to 13 times for W6Mo5Cr4V2 high-speed tool steel. As a result of the completion of the growth of reinforcing fibers in the volume of the W6Mo5Cr4V2 high-speed tool steel, the material’s bending strength in 1.2 times is realized. Simultaneously, it provides an increase of wear resistance 1.7–1.8 times.     

Process Chain Development for the Fabrication of Three-Dimensional Braided Oxide Ceramic Matrix Composites

Fiber composites with a three-dimensional braided reinforcement architecture have higher fiber volume content and Z-fiber content compared to a two-dimensional braided reinforcement architecture; as a result, the shear strength increases. Porous oxide fiber composites (OFCs) have the inherent weakness of a low interlaminar shear strength, which can be specifically increased by the use of a three-dimensional fiber reinforcement. In this work, the braiding process chain for processing highly brittle oxide ceramic fibers is modified; as a consequence, a bobbin, which protects the filament, is developed and quantitatively evaluated on a test rig with regard to tension and filament breakage. Subsequently, a braiding process is designed which takes into account fiber-protecting aspects, and a three-dimensional reinforced demonstrator is produced and tested. After impregnation with an Al₂O₃-ZrO₂ slurry, by either a prepreg process or a vacuum-assisted process, as well as subsequent sintering, the three-dimensional braid-reinforced OFC exhibits an interlaminar shear strength (ILSS) which is higher than that of two-dimensional braid- or fabric-reinforced samples by 64–95%. The influence of the manufacturing process on the relative macropore content is investigated and correlated with the mechanical properties.     

A Novel Manufacturing Concept of LCP Fiber-Reinforced GPET-Based Sandwich Structures with an FDM 3D-Printed Core

The presented research was focused on the development of a new method of sandwich structure manufacturing involving FDM-printing (fused deposition modeling) techniques and compression molding. The presented concept allows for the preparation of thermoplastic-based composites with enhanced mechanical properties. The sample preparation process consists of 3D printing the sandwich’s core structure using the FDM method. For comparison purposes, we used two types of GPET (copolymer of polyethylene terephthalate)-based filaments, pure resin, and carbon fiber (CF)-reinforced filaments. The outer reinforcing layer “skins” of the sandwich structure were prepared from the compression molded prepregs made from the LCP (liquid-crystal polymer)-fiber fabric with the GPET-based matrix. The final product consisting of an FDM-printed core and LCP-based prepreg was prepared using the compression molding method. The prepared samples were subjected to detailed materials analyses, including thermal analyses (thermogravimetry-TGA, differencial scanning calorimetry-DSC, and dynamic thermal-mechanical analysis-DMTA) and mechanical tests (tensile, flexural, and impact). As indicated by the static test results, the modulus and strength of the prepared composites were slightly improved; however, the stiffness of the prepared materials was more related to the presence of the CF-reinforced filament than the presence of the composite prepreg. The main advantage of using the developed method is revealed during impact tests. Due to the presence of long LCP fibers, the prepared sandwich samples are characterized by very high impact resistance. The impact strength increased from 1.7 kJ/m² for pure GPET samples to 50.4 kJ/m² for sandwich composites. For GPET/CF samples, the increase is even greater. The advantages of the developed solution were illustrated during puncture tests in which none of the sandwich samples were pierced.     

Effects of SiC Fibers and Laminated Structure on Mechanical Properties of Ti–Al Laminated Composites

Ti/Ti–Al and SiC_f-reinforced Ti/Ti–Al laminated composites were fabricated through vacuum hot-pressure using pure Ti foils, pure Al foils and SiC fibers as raw materials. The effects of SiC fiber and a laminated structure on the properties of Ti–Al laminated composites were studied. A novel method of fiber weaving was implemented to arrange the SiC fibers, which can guarantee the equal spacing of the fibers without introducing other elements. Results showed that with a higher exerted pressure, a more compact structure with fewer Kirkendall holes can be obtained in SiC_f-reinforced Ti/Ti–Al laminated composites. The tensile strength along the longitudinal direction of fibers was about 400 ± 10 MPa, which was 60% higher compared with the fabricated Ti/Ti–Al laminated composites with the same volume fraction (60%) of the Ti layer. An in situ tensile test was adopted to observe the deformation behavior and fracture mechanisms of the SiC_f-reinforced Ti/Ti–Al laminated composites. Results showed that microcracks first occurred in the Ti–Al intermetallic layer.     

Static and Flexural Fatigue Behavior of GFRP Pultruded Rebars

This paper presents the experimental results of composite rebars based on GFRP manufactured by a pultrusion system. The bending and radial compression strength of rods was determined. The elastic modulus of GFRP rebars is significantly lower than for steel rebars, while the static flexural properties are higher. The microstructure of the selected rebars was studied and discussed in light of the obtained results—failure processes such as the delamination and fibers fracture can be observed. The bending fatigue test was performed under a constant load amplitude sinusoidal waveform. All rebars were subjected to fatigue tests under the R = 0.1 condition. As a result, the S-N curve was obtained, and basic fatigue characteristics were determined. The fatigue mechanism of bar failure under bending was further analyzed using SEM microscopy. It is worth noting that the failure and fracture mechanism plays a crucial role as a material quality indicator in the manufacturing process. The main mechanism of failure under static and cyclic loading during the bending test is widely discussed in this paper. The results obtained from fatigue tests encourage further analysis. The diametral compression test reflects the weakest nature of the composite materials based on the interlaminar compressive strength. The proposed methodology allows us to invariantly describe the experimental transversal strength of the composite materials. Considering the expected durability of the structure, the failure mechanism is likely to significantly improve their fatigue behavior under the influence of cyclic bending. The reasonable direction of searching for reinforcements of composite structures should be the improvement of the bearing capacity of the outer layers. In comparison with steel rebars (fatigue tensile test), the obtained results for GFRP are comparable in the HCF regime. It is worth noting that in the near fatigue endurance regime (2–5 × 10⁶ cycles) both rebars exhibit similar behavior.     

Experimental and Numerical Study of Low-Velocity Impact and Tensile after Impact for CFRP Laminates Single-Lap Joints Adhesively Bonded Structure

To investigate the mechanical behavior of the single-lap joints (SLJs) adhesively bonded structure of carbon fiber reinforced polymer (CFRP) laminates under the low-velocity impact (LVI) and tensile-after impact (TAI), tests and simulations were carried out. A finite element model (FEM) was established based on the cohesive zone model (CZM) and Hashin criterion to predict the damage evolution process of adhesive film, intra- and inter-laminar of the SLJs of CFRP laminates, and its effectiveness was verified by experiments. Moreover, three different overlap lengths (20 mm, 30 mm, and 40 mm) and four different impact energies (Intact joint, 10 J, 20 J, and 30 J) are considered in the present study. Finally, the effects of different impact energies and overlap lengths on the residual strength of SLJs after impact were discussed. The results divulged that numerical results of impact and TAI processes of SLJs were in good agreement with experiment results. During the impact process, the damage of the laminates was primarily fiber and matrix tensile damage, whereas the adhesive film was damaged cohesively; the areas of damage increased with the increase of impact energy, and the normal stress of the adhesive film expanded from the edge to the middle region with the increase of impact force. The influence of LVI on SLJs adhesively bonded structures was very significant, and it is not effective to obtain a higher impact resistance by increasing the overlap length. For the tensile process, the failure mode of TAI of the SLJs was interface failure, the surplus strength of the SLJs gradually decreased with the increase of the impact energy because of the smaller overlap length, the overlap length more than 30 mm, and the low energy impact has almost no effect on the residual strength of the SLJs.     

Uniaxial Tensile Behavior,Flexural Properties,Empirical Calculation and Microstructure of Multi-Scale Fiber Reinforced Cement-Based Material at Elevated Temperature

Fire is one of the most unfavorable conditions that cement-based composites can face during their service lives. The uniaxial tensile and flexural tensile properties of the steel-polyvinyl alcohol fiber-calcium carbonate whisker (CW) multi-scale fiber reinforced cement matrix composites (MSFRCs) under high temperatures are studied, including strength, deformation capacity, energy dissipation capacity, and its ability to be assessed through the empirical calculation method. The study showed that with the increase of the treatment temperature, the MSFRC residual bending strength, bending toughness, and tensile strength decreased overall, but the decline was slow at 600 °C. The peak flexural deflection and peak tensile strain of MSFRC first reduced and then increased with the increase of the temperature. As the temperature increased, the nominal stiffness of MSFRC bending and straight gradually reduced, and the rate of decline was faster than that of its strength. However, the uniaxial tensile properties were more sensitive to the temperature and degraded more rapidly. A quantitative relationship was established between MSFRC residual bending, tensile strength, and temperature. A comparison with existing research results shows that MSFRC has achieved an ideal effect of high temperature resistance. The multi-scale hybrid fiber system significantly alleviates the deterioration of cement-based composite’s mechanical properties under high temperatures. With the help of an optical microscope and scanning electron microscope (SEM), the high temperature influence mechanism on the uniaxial tensile and flexural properties of MSFRC was revealed.