Effect of Thermal Ageing on the Impact and Flexural Damage Behaviour of Carbon Fibre-Reinforced Epoxy Laminates

Novel Sustainable Composites Incorporating a Biobased Thermoplastic Matrix and Recycled Aerospace Prepreg Waste: Development and Characterization

Carbon fiber-reinforced polymer (CFRP) composite materials are widely used in engineering applications, but their production generates a significant amount of waste. This paper aims to explore the potential of incorporating mechanically recycled aerospace prepreg waste in thermoplastic composite materials to reduce the environmental impact of composite material production and promote the use of recycled materials. The composite material developed in this study incorporates a bio-based thermoplastic polymer, polyamide 11 (PA11), as the matrix material and recycled aerospace prepreg waste quasi-one-dimensionally arranged as reinforcement. Mechanical, thermal, and thermomechanical characterizations were performed through tensile, flexural, and impact tests, as well as differential scanning calorimetry (DSC) and dynamic mechanical analysis (DMA). Compared to previous studies that used a different recycled CFRP in the shape of rods, the results show that the recycled prepregs are a suitable reinforcement, enhancing the reinforcement-matrix adhesion and leading to higher mechanical properties. The tensile results were evaluated by SEM, and the impact tests were evaluated by CT scans. The results demonstrate the potential of incorporating recycled aerospace prepreg waste in thermoplastic composite materials to produce high-performance and sustainable components in the aerospace and automotive industries.

Relaxation Model of the Relations between the Elastic Modulus and Thermal Expansivity of Thermosetting Polymers and FRPs

This research was completed in the development of studies devoted to relations between the elastic modulus (MoE) and thermal expansivity (CTe) of different materials. This study, based on experimental data, confirmed the models of the relations between MoE and CTe under normal and heating temperatures for thermosetting epoxy polymers and glass-fiber FRPs in two variants (unfilled and filled by mineral additives), after the usual glassing and prolonged thermal conditioning (thermo-relaxation). The experiment was based on dilatometric and elastic deformation testing. Two models of MoE/CTe were tested: Barker's model and our authors relaxation model (MoE = f(CTe)), which is based on previous modelling of the non-linearity of the physical properties of polymers' supramolecular structures. The result show that the models' constants depend on composition; Barker's model is applicable only to polymers with satisfying agreement degrees in the range 10-20%; our model is applicable to polymers and FRPs with satisfying agreement degrees in the range of 6-18%.

The Study of Chemical and Thermal Influences of the Environment on the Degradation of Mechanical Properties of Carbon Composite with Epoxy Resin

The present research deals with the investigation of the influence of aqueous solutions of chemical substances in combination with temperature on the change of material properties of polymer composites based on epoxy resins reinforced with carbon fibers. The aim of the research was to investigate and evaluate the impact of degradation processes due to the influence of chemical environments of different temperatures and time of their action on changes in the material properties and macrostructure of carbon composite with epoxy resin. The chemical and thermal influence of the environment on the experimental material was evaluated by monitoring changes in mechanical properties, glass transition temperature, and material surface macrostructure. The achieved results show different behavior of the experimental composite material in different environments, while it was demonstrated that the degradation effect of chemical and thermal influences on changes in material properties increase with increasing temperature. Among the investigated environments (NaCl, NaOH, and H₂SO₄), exposure to 10% NaOH, and 15% H₂SO₄ had the greatest degradation influence on the polymer composite, and exposure to 20% NaCl had the smallest influence, which is also confirmed by invisible changes in material surface macrostructure and decrease of tensile strength by about 20%. Exposure to 10% NaOH resulted in significant surface roughening of the epoxy resin, white deposit creation on the surface, and a decrease of tensile strength by 35%. Opposite that, exposure to 15% H₂SO₄ resulted in the highlighting of the fiber yarns of the carbon fiber fabric, yellowing of the surface, surface pore occurrence, and a decrease of tensile strength by 35%.

Effect of Thermal Exposure on Residual Properties of Wet Layup Carbon Fiber Reinforced Epoxy Composites

Ambient cured wet layup carbon fiber reinforced epoxy composites used extensively in the rehabilitation of infrastructure and in structural components can be exposed to elevated temperature regimes for extended periods of time of hours to a few days due to thermal excursions. These may be severe enough to cause a significant temperature rise without deep charring as through fires at a small distance and even high-temperature industrial processes. In such cases, it is critical to have information related to the post-event residual mechanical properties and damage states. In this paper, composites are subjected to a range of elevated temperatures up to 260 °C over periods of time up to 72 h. Exposure to elevated temperature regimes is noted to result in a competition between the mechanisms of post-cure that can increase the levels of mechanical characteristics, and the deterioration of the resin and the bond between the fibers and resin that can reduce them. Mechanical tests indicate that tensile and short beam shear properties are not affected negatively until the highest temperatures of exposure considered in this investigation. In contrast, all elevated temperature conditions cause deterioration in resin-dominated characteristics such as shear and flexure, emphasizing the weakness of this mode in layered composites formed from unidirectional fabric architectures due to resin deterioration. Transitions in failure modes are correlated through microscopy to damage progression both at the level of fiber-matrix interface integrity and through the bulk resin, especially at the inter-layer level. The changes in glass transition temperature determined through differential scanning calorimetry can be related to thresholds that indicate changes in the mechanisms of damage.

Effect of Long-Term Thermal Relaxation of Epoxy Binder on Thermoelasticity of Fiberglass Plastics: Multiscale Modeling and Experiments

The work is devoted to the prediction and experimental research of the elastic bending modulus of glass-reinforced plastics with an epoxy matrix on anhydride hardener reinforced with different glass fabrics. Experimental studies have been carried out to assess the effect of thermal relaxation of the polymer matrix structure due to long-term exposure to elevated temperatures (above the glass transition temperature of the polymer matrix) on the GRP elastic bending modulus at temperatures ranging from 25 to 180 °C. It has been shown that due to the thermal relaxation of the polymer matrix structure, the GRP modulus increases significantly at temperatures above 110 °C and decreases slightly at lower temperatures. Using a multiscale simulation based on a combination of the finite-element homogenization method in the Material Designer module of the ANSYS software package and three-point bending simulation in the ANSYS APDL module, the elastic modulus of FRP was predicted concerning the temperature, its averaged structural properties, and thermal relaxation of the polymer matrix structure. We have also carried out the prediction of the temperature dependences of the modulus of elasticity of glass-reinforced plastics on different types of glass fabrics in the range from 25 to 200 °C by using the entropic approach and the layered model.

Dynamic Mechanical Analysis of Thermally Aged Fique Fabric-Reinforced Epoxy Composites

Dynamic mechanical analysis (DMA) is one of the most common methods employed to study a material’s viscoelastic properties. The effect of thermal aging on plain epoxy and a fique fabric-reinforced epoxy composite was investigated by comparing the mass loss, morphologies, and DMA properties of aged and unaged samples. In fact, thermal aging presents a big challenge for the high-temperature applications of natural fiber composites. In this work, both plain epoxy and fique fabric-reinforced epoxy composite were found to have different molecular mobility. This leads to distinct transition regions, with different changes in intensity caused by external loadings from time-aging. Three exponentially modified Gauss distribution functions (EMGs) were applied to loss factor curves of fique fabric-reinforced epoxy composite and plain epoxy, which allowed identifying three possible mobility ranges. From these results it was proposed that the thermal degradation behavior of natural fibers, especially fique fiber and their composites, might be assessed, based on their structural characteristics and mechanical properties.

Declining Performance of Silicone-Based Magnetorheological Elastomers after Accelerated Weathering

Magnetorheological elastomers (MRE)-based products are usually located in an area directly exposed to sunlight and rain. However, there is no specific research on the behavior of MRE after accelerated weathering. Therefore, in this study, the changes to the chemical and rheological properties of both isotropic and anisotropic MRE after accelerated weathering were examined. Treated and untreated specimens were compared. MRE specimens with 40% by weight CIP were prepared with no current excitation and another sample was prepared with 1.5 T of magnetic flux density. Each specimen was treated in an accelerated weathering machine, Q-Sun Xe-1 Xenon Test Chamber, under a UV light exposure cycle and water spray. A material characterization was carried out using FTIR and a rheometer to determine the changes to the chemical and rheological properties. The morphological analysis results showed that after the weather treatment, the surface was rough and more cavities occurred. The rheometer test results showed a significant decrease in the storage modulus of each treated MRE specimen, unlike the untreated MRE specimens. The decrease in the storage modulus value with currents of 0, 1, 2, and 3 Amperes was 66.67%, 78.9%, 85.2%, and 80.5%, respectively. Meanwhile, FTIR testing showed a change in the wave peak between the untreated and treated MRE specimens. Thermogravimetric analysis (TGA) also showed a decrease in MRE weight for each specimen. However, for both treated and untreated MRE specimens, the decrease in TGA was not significantly different. In all the tests carried out on the MRE samples, weather acceleration treatment caused significant changes. This is an important consideration for developers who choose silicone as the MRE matrix.

Carbon Fiber Reinforced Composites: Study of Modification Effect on Weathering-Induced Ageing via Nanoindentation and Deep Learning

The exposure of carbon-fiber-reinforced polymers (CFRPs) to open-field conditions was investigated. Establishment of structure-property relations with nanoindentation enabled the observation of modification effects on carbon-fiber interfaces, and impact resistance. Mapping of nanomechanical properties was performed using expectation-maximization optimization of Gaussian fitting for each CFRPs microstructure (matrix, interface, carbon fiber), while Weibull analysis connected the weathering effect to the statistically representative behavior of the produced composites. Plasma modification demonstrated reduced defect density and improved nanomechanical properties after weathering. Artificial intelligence for anomaly detection provided insights on condition monitoring of CFRPs. Deep-learning neural networks with three hidden layers were used to model the resistance to plastic deformation based on nanoindentation parameters. This study provides new assessment insights in composite engineering and quality assurance, especially during exposure under service conditions.

Carbonaceous Materials Coated Carbon Fibre Reinforced Polymer Matrix Composites

Carbon fibre reinforced polymer composites have high mechanical properties that make them exemplary engineered materials to carry loads and stresses. Coupling fibre and matrix together require good understanding of not only fibre morphology but also matrix rheology. One way of having a strongly coupled fibre and matrix interface is to size the reinforcing fibres by means of micro- or nanocarbon materials coating on the fibre surface. Common coating materials used are carbon nanotubes and nanofibres and graphene, and more recently carbon black (colloidal particles of virtually pure elemental carbon) and graphite. There are several chemical, thermal, and electrochemical processes that are used for coating the carbonous materials onto a carbon fibre surface. Sizing of fibres provides higher interfacial adhesion between fibre and matrix and allows better fibre wetting by the surrounded matrix material. This review paper goes over numerous techniques that are used for engineering the interface between both fibre and matrix systems, which is eventually the key to better mechanical properties of the composite systems.

Effect of Thermal Ageing on the Mechanical Strength of Carbon Fibre Reinforced Epoxy Composites

Applications of Carbon Fibre Reinforced Polymers (CFRP) at temperatures over 150-200 °C are becoming common in aerospace and automotive applications. Exposure of CFRP to these temperatures can lead to permanent changes in their mechanical properties. In this work, we investigated the effect of thermal ageing in air on the strength of carbon fabric/epoxy composites. To this end, accelerated artificial ageing at different temperatures was performed on carbon fabric/epoxy specimens. The flexural and interlaminar shear strengths of the aged specimens were assessed by three-point bending and short beam shear tests, respectively, and compared to those of unaged samples. For ageing at temperatures below the glass transition temperature of the resin, Tg, a moderate reduction of strength was found, with a maximum decrease of 25% for 2160 h at 75% Tg. On the other hand, a rapid strength decrease was observed for ageing temperatures above Tg. This was attributed to degradation of the epoxy matrix and of the fibre/epoxy interface. In particular, a 30% strength decrease was found for less than 6 h at 145% Tg. Therefore, it was concluded that even a short exposure to operating temperatures above Tg could substantially impair the load-carrying capability of CFRP components.

Comparative Study of the Reinforcement Type Effect on the Thermomechanical Properties and Burning of Epoxy-Based Composites

Aramid (AF), glass (GF), carbon (CF), basalt (BF), and flax (FF) fibers in the form of fabrics were used to produce the composites by hand-lay up method. The use of fabrics of similar grammage for composites’ manufacturing allowed for a comprehensive comparison of the properties of the final products. The most important task was to prepare a complex setup of mechanical and thermomechanical properties, supplemented by fire behavior analysis, and discuss both characteristics in their application range. The mechanical properties were investigated using tensile and flexural tests, as well as impact strength measurement. The investigation was improved by assessing thermomechanical properties under dynamic deformation conditions (dynamic mechanical–thermal analysis (DMTA)). All products were subjected to a fire test carried out using a cone calorimeter (CC).

Thermal Aging Rheological Behavior of Magnetorheological Elastomers Based on Silicone Rubber

Engineering rubber composites have been widely used as main components in many fields including vehicle engineering and biomedical applications. However, when a rubber composite surface area is exposed to heat or sunlight and over a long-term accelerated exposure and lifecycle of test, the rubber becomes hard, thus influencing the mechanical and rheological behavior of the materials. Therefore, in this study, the deterioration of rheological characteristics particularly the phase shift angle (δ) of silicone rubber (SR) based magnetorheological elastomer (MRE) is investigated under the effect of thermal aging. SR-MRE with 60 wt% of CIPs is fabricated and subjected to a continuous temperature of 100 °C for 72 h. The characterization of SR-MRE before and after thermal aging related to hardness, micrograph, and rheological properties are characterized using low vacuum scanning electron microscopy (LV-SEM) and a rheometer, respectively. The results demonstrated that the morphological analysis has a rough surface and more voids occurred after the thermal aging. The hardness and the weight of the SR-MRE before and after thermal aging were slightly different. Nonetheless, the thermo-rheological results showed that the stress-strain behavior have changed the phase-shift angle (δ) of SR-MRE particularly at a high strain. Moreover, the complex mechanism of SR-MRE before and after thermal aging can be observed through the changes of the 'in-rubber structure' under rheological properties. Finally, the relationship between the phase-shift angle (δ) and the in-rubber structure due to thermal aging are discussed thoroughly which led to a better understanding of the thermo-rheological behavior of SR-MRE.

Effects of aging process and testing temperature on the open-hole compressive properties of a carbon fiber composite

The properties of T800 carbon fiber–epoxy composite specimens with a hole were studied in terms of mass change, scanning electron microscopy, glass transition temperature ( T g), heat-resistant temperature, Fourier-transform infrared (FTIR) spectroscopy, open-hole compressive strength at different temperatures, and stereomicroscopic observations after being subjected to hygrothermal aging and thermal-oxidative aging processes. FTIR spectra indicated that after hygrothermal aging at 70°C and 85% relative humidity (RH), chemical aging did not occur, whereas after thermal-oxidative aging at 190°C, the specimens exhibited chemical aging. The unaged specimens had a T g of 229°C and an extreme heat-resistant temperature T gmod of 184°C; after hygrothermal aging, the specimens had a T g and T gmod of 207°C and 143°C, respectively; and after thermal-oxidative aging, the specimens had a T g and T gmod of 252°C and 215°C, respectively. The effects of temperature on open-hole compressive strength were evaluated at room temperature of 23°C, 50°C, 100°C, 150°C, and 200°C. The compressive strengths of the specimens decreased after aging and with the increasing test temperature. At the highest test temperature, the unaged specimens, hygrothermal-aged, and thermal-oxidative-aged specimens retained over 73.7%, 65.5%, and 67.9%, respectively, of their compressive strength. Thus, the T800 carbon fiber–epoxy composite evaluated in this study exhibited good resistance to the effects of aging and high temperature. These results should be beneficial to the understanding of the long-term performance of composites.

Influence of Thermally-Accelerated Aging on the Dynamic Mechanical Properties of HTPB Coating and Crosslinking Density-Modified Model for the Payne Effect

Hydroxyl terminated polybutadiene (HTPB) coating is widely used in a solid rocket motor, but an aging phenomenon exists during long-term storage, which causes irreversible damage to the performance of this HTPB coating. In order to study the effect of aging on the dynamic mechanical properties of the HTPB coating, the thermally-accelerated aging test was carried out. The variation of maximum elongation and crosslinking density with aging time was obtained, and a good linear relationship between maximum elongation and crosslinking density was found by correlation analysis. The changing regularity of dynamic mechanical properties with aging time was analyzed. It was found that with the increase of aging time, Tg of HTPB coating increased, Tα, tan β and tan α decreased, and the functional relationships between the loss factor parameters and crosslinking density were constructed. The storage modulus and loss modulus of HTPB coating increased with the increase of aging time, and decreased with the increase of pre-strain. The aging enhanced the Payne effect of HTPB coating, while the pre-strain had a weakening effect. In view of the Payne effect of HTPB coating, the crosslinking density was introduced into Kraus model as aging evaluation parameter, and the crosslinking density modified models with and without pre-strain were established. The proposed models can effectively solve the problem that the Kraus model has a poor fitting effect under the condition of small strain (generally less than 1%) and on the loss modulus, which have improved the correlations between the fitting results and the test results.

Comparison of Self-Etching Ceramic Primer and Conventional Silanization to Bond Strength in Cementation of Fiber Reinforced Composite Post

Various mechanical and chemical surface treatments have been proposed to improve the retention of fiber-reinforced composite post (FRCP), but the results are still controversial. The bond strength and durability of a self-etching ceramic primer, which was recently released as an alternative to etching and silane, are not yet known. This study aimed to compare and evaluate the push-out bond strength of different surface treatments of FRCPs after an artificial aging procedure. Four groups (n = 10) were established to evaluated FRCP surface treatments (dentin adhesive bonding; silane and adhesive bonding; hydrofluoric acid, silane and adhesive bonding; and a self-etching ceramic primer). They were bonded with dual-curing rein cement (Multilink N) and stored in distilled water at 37 °C for 30 days, then thermal cycled for 7500 cycles. After being sectioned into 1 mm thickness, each coronal and apical part was evaluated for its the push-out bond strength by a universal testing machine. Each debonded specimen was observed by an optical microscope and divided according to the failure modes. The results showed that silane treatment significantly improved push-out bond strength, but the self-etching ceramic primer did not do so. Additional hydrofluoric acid treatment or the adhesive bonding agent alone did not significantly improve the retention of FRCPs. Cohesive failure of the luting material was found most frequently in all groups.

Effect of Thermal Ageing on the Impact Damage Resistance and Tolerance of Carbon-Fibre-Reinforced Epoxy Laminates

Composite structures are particularly vulnerable to impact, which drastically reduces their residual strength, in particular, at high temperatures. The glass-transition temperature (Tg) of a polymer is a critical factor that can modify the mechanical properties of the material, affecting its density, hardness and rigidity. In this work, the influence of thermal ageing on the low-velocity impact resistance and tolerance of composites is investigated by means of compression after impact (CAI) tests. Carbon-fibre-reinforced polymer (CFRP) laminates with a Tg of 195 °C were manufactured and subjected to thermal ageing treatments at 190 and 210 °C for 10 and 20 days. Drop-weight impact tests were carried out to determine the impact response of the different composite laminates. Compression after impact tests were performed in a non-standard CAI device in order to obtain the compression residual strength. Ultrasonic C-scanning of impacted samples were examined to assess the failure mechanisms of the different configurations as a function of temperature. It was observed that damage tolerance decreases as temperature increases. Nevertheless, a post-curing process was found at temperatures below the Tg that enhances the adhesion between matrix and fibres and improves the impact resistance. Finally, the results obtained demonstrate that temperature can cause significant changes to the impact behaviour of composites and must be taken to account when designing for structural applications.