Characterization of PPS Piston and Packing Ring Materials for High-Pressure Hydrogen Applications

The widespread adoption of renewable energy hinges on the efficient transportation of hydrogen. Reciprocating piston compressor technology in non-lubricated operation will play a key role, ensuring high flow rates and compression ratios. These systems rely on advanced high-strength sealing solutions for piston and rod packing rings utilizing advanced fiber-reinforced polymers. Polyphenylene sulfide (PPS) polymer matrix composites have seen use in tribological applications and promise high mechanical strength and wear resistance. The presented work describes carbon and glass fiber-reinforced PPS matrix polymers in comparison, which are characterized by complementary methods to investigate their properties and potential for application in reciprocating compressor under non-lubricated operation. Thermo-mechanical and tribological testing was supported by microstructure analysis utilizing advanced X-ray and electron imaging techniques. New insights in micromechanical deformation behavior in regard to fiber materials, interface strength and orientation in fiber-reinforced polymers are given. Conclusions on the suitability of different PPS matrix composites for high-pressure hydrogen compression applications were obtained.

Cognizant Fiber-Reinforced Polymer Composites Incorporating Seamlessly Integrated Sensing and Computing Circuitry

Structural fiber-reinforced polymer (FRP) composite materials consisting of a polymer matrix reinforced with layers of high-strength fibers are used in numerous applications, including but not limited to spacecraft, vehicles, buildings, and bridges. Researchers in the past few decades have suggested the necessary integration of sensors (e.g., fiber optic sensors) in polymer composites to enable health monitoring of composites' performance over their service lives. This work introduces an innovative cognizant composite that can self-sense, compute, and implement decisions based on sensed values. It is a critical step towards smart, resilient infrastructure. We describe a method to fabricate textile sensors with flexible circuitry and a microcontroller within the polymer composite, enabling computational operations to take place in the composite without impacting its integrity. A microstructural investigation of the sensors showed that the amount of oxidative agent and soaking time of the fabric play a major role in the adsorption of polypyrrole (PPy) on fiberglass (FG). XPS results showed that the 10 g ferric chloride solution with 6 h of soaking time had the highest degree of protonation (28%) and, therefore, higher adsorption of PPy on FG. A strain range of 30% was achieved by examining different circuitry and sensor designs for their resistance and strain resolution under mechanical loading. A microcontroller was added to the circuit and then embedded within a composite material. This composite system was tested under flexural loading to demonstrate its self-sensing, computing, and actuation capabilities. The resulting cognizant composite demonstrated the ability to read resistance values and measure strain using the embedded microcontroller and autonomously actuate an LED light when the strain exceeds a predefined limit of 2000 µε. The application of the proposed FRP system would provide in situ monitoring of structural composite components with autonomous response capabilities, as well as reduce manufacturing, production, and maintenance costs.

Additive Manufacturing of Large Coreless Filament Wound Composite Elements for Building Construction

Digitization and automation are essential tools to increase productivity and close significant added-value deficits in the building industry. Additive manufacturing (AM) is a process that promises to impact all aspects of building construction profoundly. Of special interest in AM is an in-depth understanding of material systems based on their isotropic or anisotropic properties. The presented research focuses on fiber-reinforced polymers, with anisotropic mechanical properties ideally suited for AM applications that include tailored structural reinforcement. This article presents a cyber-physical manufacturing process that enhances existing robotic coreless Filament Winding (FW) methods for glass and carbon fiber-reinforced polymers. Our main contribution is the complete characterization of a feedback-based, sensor-informed application for process monitoring and fabrication data acquisition and analysis. The proposed AM method is verified through the fabrication of a large-scale demonstrator. The main finding is that implementing AM in construction through cyber-physical robotic coreless FW leads to more autonomous prefabrication processes and unlocks upscaling potential. Overall, we conclude that material-system-aware communication and control are essential for the efficient automation and design of fiber-reinforced polymers in future construction.

Maintenance and Inspection of Fiber-Reinforced Polymer (FRP) Bridges: A Review of Methods

Fiber-reinforced polymers (FRPs) are materials that comprise high-strength continuous fibers and resin polymer, and the resins comprise a matrix in which the fibers are embedded. As the technique of FRP production has advanced, FRPs have attained many incomparable advantages over traditional building materials such as concrete and steel, and thus they play a significant role in the strengthening and retrofitting of concrete structures. Bridges that are built out of FRPs have been widely used in overpasses of highways, railways and streets. However, damages in FRP bridges are inevitable due to long-term static and dynamic loads. The health of these bridges is important. Here, we review the maintenance and inspection methods for FRP structures of bridges and analyze the advantages, shortcomings and costs of these methods. The results show that two categories of methods should be used sequentially. First, simple methods such as visual inspection, knock and dragging-chain methods are used to determine the potential damage, and then radiation, modal analysis and load experiments are used to determine the damage mode and degree. The application of FRP is far beyond the refurbishment, consolidation and construction of bridges, and these methods should be effective to maintain and inspect the other FRP structures.

An Efficient and Adaptable Path Planning Algorithm for Automated Fiber Placement Based on Meshing and Multi Guidelines

Path planning algorithms for automated fiber placement are used to determine the directions of the fiber paths and the start and end positions on the mold surfaces. The quality of the fiber paths determines largely the efficiency and quality of the automated fiber placement process. The presented work investigated an efficient path planning algorithm based on surface meshing. In addition, an update method of the datum direction vector via a guide-line update strategy was proposed to make the path planning algorithm applicable for complex surfaces. Finally, accuracy analysis was performed on the proposed algorithm and it can be adopted as the reference for the triangulation parameter selection for the path planning algorithm.

Post-Fire Characteristics of Concrete Beams Reinforced with Hybrid FRP Bars

One of the main concerns of experimental and numerical investigations regarding the behavior of fiber-reinforced polymer reinforced concrete (FRP-RC) members is their fire resistance to elevated temperatures and structural performance at and after fire exposure. However, the data currently available on the behavior of fiber-reinforced polymer (FRP) reinforced members related to elevated temperatures are scarce, specifically relating to the strength capacity of beams after being subjected to elevated temperatures. This paper investigates the residual strength capacity of beams strengthened internally with various (FRP) reinforcement types after being subjected to high temperatures, reflecting the conditions of a fire. The testing was made for concrete beams reinforced with three different types of FRP bars: (i) basalt-FRP (BFRP), (ii) hybrid FRP with carbon and basalt fibers (HFRP) and (iii) nano-hybrid FRP (nHFRP), with modification of the epoxy matrix of the rebar. Tested beams were first loaded at 50% of their ultimate strength capacity, then unloaded before being heated in a furnace and allowed to cool, and finally reloaded flexurally until failure. The results show an atypical behavior observed for HFRP bars and nHFRP bars reinforced beams, where after a certain temperature threshold the deflection began to decrease. The authors suggest that this phenomenon is connected with the thermal expansion coefficient of the carbon fibers present in HFRP and nHFRP bars and therefore creep can appear in those fibers, which causes an effect of “prestressing” of the beams.

Novel Repair Concept for Composite Materials by Repetitive Geometrical Interlock Elements

Material adapted repair technologies for fiber-reinforced polymers with thermosetting matrix systems are currently characterized by requiring major efforts for repair preparation and accomplishment in all industrial areas of application. In order to allow for a uniform distribution of material and geometrical parameters over the repair zone, a novel composite interlock repair concept is introduced, which is based on a repair zone with undercuts prepared by water-jet technology. The presented numerical and experimental sensitivity analyses make a contribution to the systematic development of the interlock repair technology with respect to material and geometrical factors of influence. The results show the ability of the novel concept for a reproducible and automatable composite repair.