Wettability and Interfacial Properties of Carbon Fiber and Poly(ether ether ketone) Fiber Hybrid Composite

Study on the Preparation and Process Parameter-Mechanical Property Relationships of Carbon Fiber Fabric Reinforced Poly(Ether Ether Ketone) Thermoplastic Composites

Carbon fiber fabric-reinforced poly(ether ether ketone) (CFF-PEEK) composites exhibit exceptional mechanical properties, and their flexibility and conformability make them a promising alternative to traditional prepregs. However, the formation of the CFF-PEEK composite is trapped in the high viscosity of PEEK, the smooth surface, and tightly interwoven bundles of CFF. It is more difficult for the resin to flow through the fibers of complex textile structures. Here, a simple film stacking method using the hot-pressing process of plain-woven CFF-PEEK thermoplastic composites is discussed. The uniform distribution of PEEK resin between each layer of CFF reduces the flow distance during the molding process, preventing defects in the composite material effectively. Four process parameters, including molding temperature (370, 385, 400, and 415 °C), molding pressure (1, 2, 4, 8, and 10 MPa), molding time (10, 20, 30, 40, 60, and 90 min), and pre-compaction process, are considered. Interlaminar shear strength (ILSS), tensile strength, and flexural strength of CFF/PEEK composites are evaluated to optimize the process parameters. Moreover, ultrasonic scanning microscopy and scanning electron microscopy are employed to observe the formation quality and microscopic failure modes of CFF/PEEK composites, respectively. The ultimate process parameters are a molding temperature of 410 °C, molding pressure of 10 MPa, molding time of 60 min, and the need for the pre-compaction process. Under the best process parameters, the ILSS is 62.5 MPa, the flexural strength is 754.4 MPa, and the tensile strength is 796.1 MPa. This work provides valuable insight for studying the process parameters of fiber fabric-reinforced thermoplastic polymer composites and revealing their impact on mechanical properties.

Taguchi optimization of 3D printed short carbon fiber polyetherketoneketone (CFR PEKK)

In this study, the Taguchi method was utilized to optimize fused filament fabrication (FFF) additive manufacturing with the goal of maximizing the flexural strength of 3D printed polyaryletherketone specimens. We analyzed 3D printed (3DP) carbon fiber reinforced poly-etherketoneketone (CFR PEKK), 3D printed and pressed (3DP + P) CFR PEKK, and injection molded medical grade polyetheretherketone (PEEK) as a control. Fracture surfaces were analyzed via scanning electron microscopy (SEM). The parameters that were varied in the optimization included nozzle diameter, layer height, print speed, raster angle, and nozzle temperature. We analyzed the flexural strength and flexural modulus determined from 3-point bending (ASTM D790). Using Taguchi optimization, the signal to noise ratio (SNR) was calculated to determine the relationship between the input parameters and flexural strength and to determine optimal print settings. Results were confirmed with analysis of variance (ANOVA). The raster angle and layer height were determined to have the greatest impact on the flexural strength of specimens printed in the FFF process for 3DP CFR PEKK. The optimized printing parameters were found to be 0/90 Raster Angle, 0.25 mm layer height, 0.8 mm Nozzle Diameter, 375 °C nozzle temperature, and 1100 mm/min print speed. The optimized 3DP CFR PEKK test samples had a flexural strength of 111.3 ± 5.3 MPa and a flexural modulus of 3.5 GPa. 3DP + P CFR PEKK samples had a flexural strength of 257.2 ± 17.8 MPa and a flexural modulus of 8.2 GPa. Statistical comparisons between means demonstrated that pressing significantly improves both flexural strength and flexural modulus of 3DP CFR PEKK. The results of this study support the hypothesis that post consolidation of 3DP specimens improves mechanical properties. Post-processing composites via pressing may allow greater design freedom within the 3DP process while improving mechanical properties.

InSitu Integrated Fabrication for Multi-Interface Stabilized and Highly Durable Polyaniline@Graphene Oxide/Polyether Ether Ketone Special Separation Membranes

Special separation membranes are widely employed for separation and purification purposes under challenging operating conditions due to their low energy consumption, excellent solvent, and corrosion resistance. However, the development of membranes is limited by corrosion-resistant polymer substrates and precise interfacial separation layers. Herein, polyaniline (PANI) is employed to achieve insitu anchoring of multiple interfaces, resulting in the fabrication of polyaniline@graphene oxide/polyether ether ketone (PANI@GO/PEEK) membranes. Insitu growth of PANI achieves the adequate bonding of the PEEK substrate and GO separation interface, which solves the problem of solution processing of PEEK and the instability of GO layers. By bottom-up confined polymerization of aniline, it could control the pore size of the separation layer, correct defects, and anchor among polymer, nano-separation layer, and nano-sheet. The mechanism of membrane construction within the confined domain and micro-nano structure modulation is further explored. The membranes demonstrate exceptional stability realizing over 90% rejection in 2 m HCl, NaOH, and high temperatures. Additionally, -membranes exhibit remarkable durability after 240 days immersion and 100 h long-term operation, which display the methanol flux of 50.2 L m-2 h-1 and 92% rejection of AF (585 g mol-1 ). This method substantially contributes to special separation membranes by offering a novel strategy.

Wet-Spun Porous Carbon Microfibers for Enhanced Electrochemical Detection

We present a novel copolymer-based, uniform porous carbon microfiber (PCMF) formed via wet-spinning for significantly improved electrochemical detection. Carbon fiber (CF), fabricated from a polyacrylonitrile (PAN) precursor, is commonly used in batteries or for electrochemical detection of neurochemicals due to its biplanar geometry and desirable edge plane sites with high surface free energy and defects for enhanced analyte interactions. Recently, the presence of pores within carbon materials has presented interesting electrochemistry leading to detection improvements; however, there is currently no method to uniformly create pores on a carbon microfiber surface impacting a broad range of electrochemical applications. Here, we synthesized controllable porous carbon fibers from a spinning dope of the copolymers PAN and poly(methyl methacrylate) (PMMA) in dimethylformamide via wet spinning for the first time. PMMA serves as a sacrificial block introducing macropores of increased edge-plane character on the fiber. Methods were optimized to produce porous CFs at similar dimensions to traditional CF. We prove that an increase in porosity enhances the degree of disorder on the surface, resulting in significantly improved detection capabilities with fast-scan cyclic voltammetry. Local trapping of analytes at porous geometries enables electrochemical reversibility with improved sensitivity, linear range of detection, and measurement temporal resolution. Overall, we demonstrate the utility of a copolymer synthetic method for PCMF fabrication, providing a stable, controlled macroporous fiber framework with enhanced edge plane character. This work will significantly advance fundamental investigations of how pores and edge plane sites influence electrochemical detection.

Understanding the Interfacial Adhesion between Natural Silk and Polycaprolactone for Fabrication of Continuous Silk Biocomposites

The poor interfacial adhesion between silk fiber and polyester species remains a critical problem for the optimal mechanical performance of silk-reinforced polyester composites. Here, we investigated in quantitative terms the interfacial properties between natural silk fibers and polycaprolactone (PCL) at nano-, micro-, and macroscales and fabricated continuous silk-PCL composite filaments by melt extrusion and drawing processing of PCL melt at 100, 120, and 140 °C. Bombyx mori (Bm) silk, Antheraea pernyi (Ap) silk, and polyamide6 (PA6) fiber were compared to the composite with PCL. The Ap silk exhibited the highest surface energy, the best wettability, and the largest interfacial shear strength (IFSS) with PCL. The silk-PCL composite from the 120 °C melt processing displayed the highest tensile modulus, implying an optimal temperature for interfacial adhesion. The Raman imaging technique revealed in detail the nature of the physical fusion of the interface phase in these silk- and polyamide-reinforced PCL composites. This work is intended to lay a foundation for the design and processing of robust composites from continuous silk fibers and bioresorbable polyesters for potential structural biomaterials.

Robust and durable liquid-repellent surfaces

This review provides a comprehensive summary of characterization, design, fabrication, and application of robust and durable liquid-repellent surfaces.

Based On Confined Polymerization: In Situ Synthesis of PANI/PEEK Composite Film in One-Step

Confined polymerization is an effective method for precise synthesis, which can further control the micro-nano structure inside the composite material. Polyaniline (PANI)-based composites are usually prepared by blending and original growth methods. However, due to the strong rigidity and hydrogen bonding of PANI, the content of PANI composites is low and easy to agglomerate. Here, based on confined polymerization, it is reported that polyaniline /polyether ether ketone (PANI/PEEK) film with high PANI content is synthesized in situ by a one-step method. The micro-nano structure of the two polymers in the confined space is further explored and it is found that PANI grows in the free volume of the PEEK chain, making the arrangement of the PEEK chain more orderly. Under the best experimental conditions, the prepared 16 µm-PANI/PEEK film has a dielectric constant of 205.4 (dielectric loss 0.401), the 75 µm-PANI/PEEK film has a conductivity of 3.01×10-4 S m-1 . The prepared PANI/PEEK composite film can be further used as electronic packaging materials, conductive materials, and other fields, which has potential application prospects in anti-static, electromagnetic shielding materials, corrosion resistance, and other fields.

Evaluation of Viscosity Dependence of the Critical Meniscus Height with Optical Fiber Sensors

Conventional means of data extraction using optical fiber interrogators are not adequate for fast-paced detection of a target parameter. In this instance, the relationship between the critical meniscus heights (CMH) of several liquids to the extraction speed of a rod submerged in them, have been analyzed. A limitation of a previous interrogator used for the purpose had been light absorption by the liquid due to the used bandwidth of the readily-available light source, i.e., C-band. The newly proposed technique addresses this limitation by utilizing a broadband light source instead, with a Si-photodetector and an Arduino. In addition, the Arduino is capable of extracting data at a relatively faster rate with respect to the conventional optical interrogator. The use of a different operational wavelength (850 nm instead of 1550 nm) increased the r² and the sensitivity of the sensor. The new setup can measure surface chemistry properties, with the advantage of being comparatively cheaper than the conventionally available interrogator units, thereby providing a suitable alternative to conventional measurement techniques of liquid surface properties, while reducing material waste, i.e., in terms of the required volume for detection of a target parameter, through the use of optical fiber.

Preparation of ultra-high mechanical strength wear-resistant carbon fiber textiles with a PVA/PEG coating

Polyvinyl alcohol (PVA) is an organic polymer that is non-toxic, harmless to the human body, and has good biocompatibility. Polyethylene glycol (PEG) is a polymer that has good lubricity and compatibility. The unique graphite structure of carbon fibers can promote the potential application of carbon–fiber composites in tribology. This study explores the relationship between two kinds of organic polymer compounds and carbon fiber cloth (CFC), specifically a PVA/PEG composite coating that is impregnated on the CFC surface. The CFC is synthesized by chemical cross-linking, and the CFC composites (PVA/PEG/CFC) were synthesized. The tribological properties of PVA/PEG/CFC were tested under different concentrations, loads, and velocities. The effects of the different lubricants, surface morphologies, and tensile strengths on the mechanical and tribological properties of PVA/PEG/CFC were studied. In comparison to the original CFC, the friction coefficient and wear morphology of the composite material were reduced and the friction coefficient trend was stable. The addition of PVA/PEG improved the surface lubrication performance of the composite material and reduced the average friction coefficient. In addition, under the different lubrication mechanisms, oil as a lubricant can significantly reduce the friction coefficient and surface wear. In summary, the biocompatible coating process that is proposed in this study can effectively improve the tribological properties of the surface of the CFC.

Polyvinyl alcohol (PVA) is an organic polymer that is non-toxic, harmless to the human body, and has good biocompatibility. Polyethylene glycol (PEG) is a polymer that has good lubricity and compatibility. As a new coating material, PVA/PEG has good mechanical properties.

Electrode Potential Regulation of Carbon Fiber Based on Galvanic Coupling and Its Application in Electrochemical Grafting

The reaction behavior of carbon fiber in electrochemical grafting is related to its electrode potential. In this paper, carbon fiber and metals with different electrode potentials were used to form combined electrodes to regulate the electrode potential of carbon fiber. The results showed that galvanic coupling was formed in the combined anode when the potential difference between carbon fiber and the metal (Δϕ = ϕ_CF0 - ϕ_metal) was higher than 0.05 V. The electrode potential of carbon fiber was reduced due to cathodic polarization. The electrode potential of carbon fiber after galvanic coupling was proportional to the self-corrosion potential of metals. By applying the electrode potential regulation of carbon fiber in the electrochemical grafting of poly(glycidyl methacrylate) onto the carbon fiber surface, the grafting effect was significantly improved with the decrease of the electrode potential of carbon fibers. The grafting amount of carbon fibers increased from 0.83 to 69.86% as the electrode potential of carbon fibers dropped from 0.55 to -0.72 V. Consequently, the interfacial shear strength of the carbon fiber composite was remarkably promoted from 47.59 to 81.41 MPa, increasing by 71.07%.

Preparation of Poly(ether-ether-ketone)/Nanohydroxyapatite Composites with Improved Mechanical Performance and Biointerfacial Affinity

Poly(ether-ether-ketone) (PEEK) displays promising potential in hard tissue repair and orthopedic surgery due to its adaptable mechanical performance, good chemical resistance, and bioinertness. However, the low biointerfacial affinity of pure PEEK implants and the decrease of mechanical strength after processing greatly limit their clinical applications. In this work, the influences on mechanical performance and biointerfacial affinity of the PEEK/nanohydroxyapatite (nHA) composites are systematically investigated. Results show that the mechanical performance of PEEK/nHA composites was improved by adjusting the nHA content. The maximum values of the tensile, compressive, bending, and impact strength of the composites were increased by approximately 16.2, 25, 54, and 21%, respectively, when compared with that of pure PEEK. Studies in vitro show that PEEK/nHA composites display good cytocompatibility and promote the biomimic formation of HA, adhesion, and proliferation of L929 cells on the surface. Studies in vivo demonstrate that, compared to the pure PEEK, PEEK/nHA composites exhibit higher biointerfacial affinity, including the adhesion and encapsulation of muscle tissues on the surface of the implants and the suppression of inflammatory reaction around the implants. Our findings could pave the way for extensive applications of PEEK/nHA composites in hard tissue repair, particularly orthopedic surgery.

Interfacial adhesion of carbon fiber to special engineering plastics: Effect of the functional groups in the matrix

We studied the interfacial shear strength (IFSS) in carbon fiber (CF) and special engineering plastics matrix, with an emphasis on the effect of the functional group in the matrix. The IFSS was analyzed to quantify the interfacial adhesion between the fiber and the matrix. To obtain the apparent IFSS of the composites, microdroplet test was measured at single-fiber composites. Results of the microdroplet test displayed that the apparent IFSS in the composites was directly determined by their inherent surface properties and the functional groups in the matrix. Compared with other matrices, polyetherimide (PEI) exhibited relatively strong mechanical bonding and interfacial adhesion, showing that the imide groups had good interfacial compatibility with the pristine CF surface. Based on the results of this study, polymers containing imide groups were one of the best candidates for sizing agent of CF used as reinforcement of high-temperature thermoplastics.

Reinforced interface and mechanical properties of high strength carbon fiber composites

Based on the surface analysis of carbon fiber, an epoxy resin matrix with good wettability to carbon fibers had been developed and studied, and the influence of winding tension on the interface and mechanical properties of the composite were studied. The surface morphology of carbon fiber and the active functional groups of sizing agent were analyzed. In order to form a good interface combination, the wettability between carbon fibers and epoxy resin matrix was characterized by dynamic contact angle. The winding tension played an important role in the mechanical properties of composites. Therefore, a kind of carbon fiber reinforced composites, Naval Ordnance Laboratory (NOL) rings were fabricated using different winding tensions. Particularly, when the winding tension was 30 N, the interfacial bonding between carbon fibers and resin matrix was the most compact and firm. The tensile strength and interlaminar shear strength (ILSS) of NOL rings reached high values, 2712 MPa and 75 MPa, respectively.

Mussel-Inspired Co-Deposition of Polydopamine/Silica Nanoparticles onto Carbon Fiber for Improved Interfacial Strength and Hydrothermal Aging Resistance of Composites

A novel and effective strategy was first proposed for the codeposition of a mussel-inspired nanohybrid coating with excellent wettability onto the surface of carbon fibers (CFs) by simultaneous polymerization of bioinspired dopamine (DA) and hydrolysis of commercial tetraethoxysilane (TEOS) in an eco-friendly one-pot process. Mussel-inspired nanohybrids could be adhered onto the surface of CFs firmly. The novel modification could afford sufficient polar groups and significantly improve fiber surface roughness and energy without decreasing fiber intrinsic strength, which were advantageous to promote interfacial compatibility and wettability between CFs and matrix resin. As a result, the interfacial shear strength of composites increased to 48.21 ± 1.45 MPa compared to that of untreated composites 29.47 ± 0.88 MPa. Meanwhile, the nanohybrid coating increased significantly composites’ hydrothermal aging resistance. The efficient strategy shows a promising and green platform of surface functionalization of CFs for preparing advanced polymer composites arising from broadly mechanical-demanding and energy-saving usages.

Modification of Renewable Cardanol onto Carbon Fiber for the Improved Interfacial Properties of Advanced Polymer Composites

A facile in situ polymerization was developed for grafting renewable cardanol onto the carbon fiber (CF) surfaces to strengthen the fiber–matrix interface. CFs were chemically modified with hydroxyl groups by using an aryl diazonium reaction, and then copolymerized in situ with hexachlorocyclotriphosphazene (HCCP) and cardanol to build cardanol-modified fibers (CF-cardanol). The cardanol molecules were successfully introduced, as confirmed using Raman spectra and X-ray photoelectron spectroscopy (XPS); the cardanol molecules were found to increase the surface roughness, energy, interfacial wettability, and activity with the matrix resin. As a result, the interlaminar shear strength (ILSS) of CF-cardanol composites increased from 48.2 to 68.13 MPa. In addition, the anti-hydrothermal ageing properties of the modified composites were significantly increased. The reinforcing mechanisms of the fiber–matrix interface were also studied.