Stress dependence of indentation modulus for carbon fiber in polymer composite

Numerical calculation and finite element analysis for anisotropic elastic properties of carbon fibers: dependence of integration subinterval and mesh size on indentation-derived elastic modulus

The elastic modulus measured by indentation of carbon fibers with various anisotropic elasticity is calculated by two numerical approaches, the Vlassak–Nix model and finite element analysis, to reveal the acceptable calculation condition for highly anisotropic materials. Five commercially available carbon fibers that varied in anisotropy index in the range of 0.5–7.9 are used (either polyacrylonitrile- or pitch-based). The numerical error in the calculated modulus increases with the decrease in fiber angle and with the increase in the anisotropy index under the same mesh condition, indicating finer mesh is required for a highly anisotropic material. The acceptable mesh size linearly increases with anisotropic index. The Vlassak–Nix model overestimates the elastic modulus at a small tilt angle if few integration subintervals are used. Conversely, finite element analysis of the Hertz contact problem with coarse mesh underestimates the modulus at a small tilt angle, and a maximum modulus is observed when the fiber is tilted a few degrees against the indentation axis. These findings are expected to assist the future determination of ideal calculation conditions for materials with large anisotropic elasticity including fibers and composites.

Stress mapping reveals extrinsic toughening of brittle carbon fiber in polymer matrix

We conducted an in situ study on CFRP fracturing process using atomic-force-microscopy-based stress-sensitive indentation. Tensile stress distribution during fracture initiation and propagation was directly observed quantitatively. It led to a discovery that previously believed catastrophic fracture of individual carbon fiber develops in a controllable manner in the polymer matrix, exhibiting 10 times increase of fracture toughness. Plastic deformation in crack-bridging polymer matrix was accounted for the toughening mechanism. The model was applied to explain low temperature strength weakening of CFRP bulk material when matrix plasticity was intentionally 'shut down' by cryogenic cooling.

Incorporation of electroconductive carbon fibers to achieve enhanced anti-corrosion performance of zinc rich coatings

Zinc rich epoxy (ZRE) coatings can provide sacrificial anode protection for metal substrate. Electrically conductive fillers can be added into ZRE coatings to create electroconductive network and improve the utilization of zinc particles. Inspired by the structure of reinforced concrete, in this work, carbon fibers with a length of 2 mm, 5 mm, and 10 mm were used as electrically conductive fillers to drive more zinc particle into electrically conductive paths and to provide coatings with better mechanical properties. Without agglomeration, ZRE-10 can achieve an efficient protection for copper substrate up to 50 days in 3.5 wt% NaCl solution, much longer than that of ZRE coating. Moreover, the fraction of water absorbed by ZRE-10 is 14%, which for ZRE is 20%, and the adhesion strength of ZRE-10 increased by 65% compared with that of ZRE. All tests in this work can prove a remarkably enhanced anticorrosion performance and mechanical properties of ZRE coatings achieved by addition of longer carbon fibers.

Thermal Deformation of PA66/Carbon Powder Composite Made with Fused Deposition Modeling

Polyamide 66 (PA66) is a material with high wear resistance, toughness, and heat resistance. However, low stiffness and thermal deformation during thermal processes define applications in many conditions. Carbon powder efficiently enhances stiffness and reduces thermal deformation, which makes up defects of plastic materials. However, forming a composite with fused deposition modeling (FDM) that accumulates material to a specified location by melting plastic filaments is limited, including fluidity and viscosity to form normally. In this paper, filaments of polyamide 66 (PA66) reinforced with carbon powder were produced. Digimat was used to analyze the composite material properties of different carbon contents and predict the proper carbon content. Then, the material properties were imported to ANSYS software to simulate the thermal deformation of the workpieces during processing. It was verified that adding carbon powder is helpful in decreasing thermal deformation. Comparing experiments and simulations, we found that 20% carbon mass fraction was best, and that thermal deformation was minimal at 240 °C nozzle temperature while hot bed temperature was 90 °C. The optimal ratio of extrusion speed to filling speed was 0.87, and the best aspect ratio was 0.25.