Interlaminar Toughening of Epoxy Carbon Fiber Reinforced Laminates: Soluble Versus Non-Soluble Veils

A Review of Electrospun Nanofiber Interleaves for Interlaminar Toughening of Composite Laminates

Recently, polymeric nanofiber veils have gained lot of interest for various industrial and research applications. Embedding polymeric veils has proven to be one of the most effective ways to prevent delamination caused by the poor out-of-plane properties of composite laminates. The polymeric veils are introduced between plies of a composite laminate, and their targeted effects on delamination initiation and propagation have been widely studied. This paper presents an overview of the application of nanofiber polymeric veils as toughening interleaves in fiber-reinforced composite laminates. It presents a systematic comparative analysis and summary of attainable fracture toughness improvements based on electrospun veil materials. Both Mode I and Mode II tests are covered. Various popular veil materials and their modifications are considered. The toughening mechanisms introduced by polymeric veils are identified, listed, and analyzed. The numerical modeling of failure in Mode I and Mode II delamination is also discussed. This analytical review can be used as guidance for veil material selection, for estimation of the achievable toughening effect, for understanding the toughening mechanism introduced by veils, and for the numerical modeling of delamination.

A Manufacturing Process Simulation of Toughened Cyanate-Ester-Based Composite Structures with Respect to Stress Relaxation

The objectives of this study were to experimentally determine the effects of the stress relaxation of a cyanate-ester-based composite, derive and integrate constitutive equations into commercial FEM software, and apply this approach to understand the formation of residual stress in a typical aerospace structure-namely, a stiffened panel. In preliminary studies, a cyanate-ester-based composite with increased fracture toughness for high-temperature applications was developed. High curing temperatures up to 260 °C will inevitably lead to high process-induced stresses. To assess the magnitude of impact on the development of internal stresses, the relaxation behavior of the neat resin was measured and characterized. The system was toughened, and the effect of stress relaxation increased as the temperature got closer to the glass transition temperature of the toughener, which was approximately 240 °C. With the use of an incremental linear viscoelastic model, the relaxation behavior was integrated into a process model with a holistic approach. A stiffened panel was manufactured and used as the validation use case. The displacement field was validated with an optical 3D measuring system, and good agreement was found between the simulated and experimental results. The maximum difference between the elastic and the viscoelastic solution was found to be 15%. Furthermore, the stress magnitude in the transverse material direction resulted in a more critical value higher than the material strength.

Experimental Study on the Interlaminar Fracture Properties of Carbon Fibre Reinforced Polymer Composites with a Single Embedded Toughened Film

In this study, two types of single polymer films have been inserted in a composite laminate to examine their toughening effects on mechanical properties. The first is a thermoplastic polyurethane (PU) film, and the second is an adhesive epoxy film featuring a polyester net. The laminates were manufactured either using a co-curing (CC) process or a secondary bonding (SB) process used for the epoxy film. Mode I and mode II interlaminar fracture toughness were measured for laminates manufactured by both processes and compared with the corresponding reference laminate toughness. A significant increase in both mode I and mode II toughness resulted when introducing a single PU film, approximately 290% and 50%, respectively. Similarly, the epoxy film improved the interlaminar fracture properties; the CC process produced an increase of 175% for mode II toughness, while the SB adhesive film showed an increase of 75% for mode II toughness.

Rubbery-Modified CFRPs with Improved Mode I Fracture Toughness: Effect of Nanofibrous Mat Grammage and Positioning on Tanδ Behaviour

Carbon Fiber Reinforced Polymers (CFRPs) are widely used where high mechanical performance and lightweight are required. However, they suffer from delamination and low damping, severely affecting laminate reliability during the service life of components. CFRP laminates modified by rubbery nanofibers interleaving is a recently introduced way to increase material damping and to improve delamination resistance. In this work, nitrile butadiene rubber/poly(ε-caprolactone) (NBR/PCL) blend rubbery nanofibrous mats with 60 wt% NBR were produced in three different mat grammages (5, 10 and 20 g/m²) via single-needle electrospinning and integrated into epoxy CFRP laminates. The investigation demonstrated that both mat grammage and positioning affect CFRP tanδ behaviour, evaluated by dynamic mechanical analysis (DMA) tests, as well as the number of nano-modified interleaves. Double cantilever beam (DCB) tests were carried out to assess the mat grammage effect on the interlaminar fracture toughness. Results show an outstanding improvement of G_I,R for all the tested reinforced laminates regardless of the mat grammage (from +140% to +238%), while the effect on G_I,C is more dependent on it (up to +140%). The obtained results disclose the great capability of NBR/PCL rubbery nanofibrous mats at improving CFRP damping and interlaminar fracture toughness. Moreover, CFRP damping can be tailored by choosing the number and positioning of the nano-modified interleaves, besides choosing the mat grammage.

Investigation on Mode I Fracture Toughness of Woven Carbon Fiber-Reinforced Polymer Composites Incorporating Nanomaterials

This study experimentally investigated the effects of nanomaterials and interface fiber angle on the mode I fracture toughness of woven carbon fiber-reinforced polymer (CFRP) composites. Three different types of nanomaterials were used: COOH-functionalized short multi-walled carbon nanotubes (S-MWCNT-COOH), multi-walled carbon nanotubes (MWCNTs), and graphene nanoplatelets (GnPs). Double cantilever beam specimens were composed of 12 woven carbon fiber fabrics with/without 1 wt% nanomaterials, and were manufactured using the hand lay-up method. Furthermore, two different stacking sequence series were used; the first series comprised only on-axis carbon-fiber fabrics (0° or 90°), and the second series comprised both on- and off-axis carbon-fiber fabrics (0° or 90° and ±45°). The test results showed that adding S-MWCNT-COOH, MWCNTs, and GnPs significantly increased the mode I fracture toughness of the CFRP composites for both the stacking sequence series. Moreover, the specimens that used only on-axis carbon fiber fabrics exhibited higher fracture toughness values than those of the specimens that used on- and off-axis carbon fiber fabrics together. In addition, an empirical model was established to predict the fracture toughness of the CFRP composites with nanomaterials by using on- and off-axis carbon fiber fabrics together, and the prediction results showed a good agreement with the experimental results.