Exploring the tensile response in small carbon fibre composite bundles

Small composite bundles, AS4 carbon fibre epoxy, with a restricted number of reinforcing fibres, ca. 20, showed a progressive failure when tested in tension. In-situ acoustic emission observations under tensile load reveal that numerous fibres fail before ultimate failure of the small composite bundle, suggesting that isolated and individual fibre failures occur without compromising the integrity of the neighboring fibres or the small composite bundle’s overall mechanical performance. The average strength of the carbon fibres in small composite bundles was 9.6% higher than in standard lab-scale composite specimens using the same fibre type

Reactive coagulation of single-walled carbon nanotubes for tougher composites - Solution processing and assembly

The injection of reduced single-walled carbon nanotubes into a coagulation bath of polyvinyl chloride (PVC) solution leads to the formation of nanocomposite fibres with polymer covalently bound to the nanotubes. The influence of PVC concentration and molecular weight, and the extrusion diameter on the nanocomposite fibre tensile properties and composition have been examined. The nanocomposite fibres produced have strengths as high as 480 MPa and modulus of 15 GPa, making them the strongest and stiffest PVC composites recorded to date

Metal mimics: lightweight, strong, and tough (nano)composites and nanomaterial assemblies

The ideal structural material would be high strength and stiffness, with a tough ductile failure, all with a low density. Historically, no such material exists, and materials engineers have had to sacrifice a desired property during materials selection, with metals (high density), fibre composites (brittle failure), and polymers (low stiffness) having fundamental limitations on at least one front. The ongoing revolution of nanomaterials provides a potential route to build on the potential of fibre-reinforced composites, matching their strength while integrating toughening behaviours akin to metal deformations all while using low weight constituents. Here, the challenges, approaches, and recent developments of nanomaterials for structural applications are discussed, with an emphasis on improving toughening mechanisms – often the neglected factor in a field which chases strength and stiffness

Stiff monolithic aerogel matrices for structural fibre composites

Resorcinol-formaldehyde based aerogel precursors were infused into structural carbon fibre weaves, then gelled and carbonised to generate a continuous monolithic matrix network. This hierarchical carbon preform was subsequently infused with polymeric resins, both multifunctional and structural, to produce dense composites. The resulting hierarchical composites have a nanoscale reinforcement in the matrix at up to an order of magnitude higher loadings than typically available by other techniques. Compression, tension, ±45° shear and short beam tests demonstrate the potential of such matrix systems to address matrix dominated failures. However, for the best structural performance it will be necessary to re-optimise the fibre-matrix interface, which is degraded by the current processing regime

Mechanical and physical performance of carbon aerogel reinforced carbon fibre hierarchical composites

Carbon aerogel (CAG) is a potential hierarchical reinforcement to improve the matrix-dominated mechanical properties of continuous carbon fibre reinforced polymer (CFRP) composites in both multifunctional and purely structural applications. When using CAG to reinforce a polyethylene glycol diglycidyl ether (PEGDGE) matrix, the interlaminar shear strength, compressive modulus and strength increased approximately four-fold, whilst the out-of-plane electrical conductivity increased by 118%. These mechanical and electrical performance enhancements significantly improve the multifunctional efficiency of composite structural supercapacitors, which can offer weight savings in transport and other applications. However, CAG also has the potential to reinforce conventional continuous CF composites in purely structural contexts. Here, CAG reinforcement of structural epoxy resin composites marginally increased compressive (1.4%) and tensile (2.7%) moduli respectively, but considerably reduced compressive, tensile and interlaminar shear strengths. Fractographic analysis shows that the reduced performance can be attributed to poor interfacial adhesion; in the future, alternative processing routes may resolve these issues to achieve advances in both moduli and strengths over conventional structural CFRPs

Increasing carbon fiber composite strength with a nanostructured “brick-and-mortar” interphase

Conventional fiber-reinforced composites suffer from the formation of critical clusters of correlated fiber breaks, leading to sudden composite failure in tension. To mitigate this problem, an optimized “brick-and-mortar” nanostructured interphase was developed, in order to absorb energy at fiber breaks and alleviate local stress concentrations whilst maintaining effective load transfer. The coating was designed to exploit crack bifurcation and platelet interlocking mechanisms known in natural nacre. However, the architecture was scaled down by an order of magnitude to allow a highly ordered conformal coating to be deposited around conventional structural carbon fibers, whilst retaining the characteristic phase proportions and aspect ratios of the natural system. Drawing on this bioinspiration, a Layer-by-Layer assembly method was used to coat multiple fibers simultaneously, providing an efficient and potentially scalable route for production. Single fiber pull out and fragmentation tests showed improved interfacial characteristics for energy absorption and plasticity. Impregnated fiber tow model composites demonstrated increases in absolute tensile strength (+15%) and strain-to-failure (+30%), as compared to composites containing conventionally sized fibers

Structural supercapacitor composite technology demonstrator

Structural power composites, a class of multifunctional materials, have significant potential to facilitate lightweighting and accelerate widespread electrification in sustainable transportation. In civil aircraft, a bank of supercapacitors can provide power to open the doors in an emergency. Structural power composite fuselage components near the doors could provide this power and eliminate the mass and volume needed for the supercapacitors. To demonstrate this concept, we designed and manufactured a multifunctional component representative of a fuselage rib, which powered the opening and closing of a desktop scale composite aircraft door. This paper provides information about structural supercapacitor technology demonstrators, discusses the fabrication of this demonstrator and concludes by providing an insight into the future challenges that need to be addressed to realise structural power composite components

Robust single‐walled carbon nanotube‐infiltrated carbon fiber electrodes for structural supercapacitors: from reductive dissolution to high performance devices

Multifunctional electrodes for structural supercapacitors are prepared by vacuum infiltration of single-walled carbon nanotubes (SWCNTs) into woven carbon fibers (CFs); the use of reductive charging chemistry to form nanotubide solutions ensured a high degree of individualization. The route is highly versatile, as shown by comparing four different commercial nanotube feedstocks. In film form, the pure nanotubide networks (“buckypapers”) are highly conductive (up to 2000 S cm−1) with high surface area (>1000 m2 g−1) and great electrochemical performance (capacitance of 101 F g−1, energy density of 27.5 Wh kg−1 and power density of 135 kW kg−1). Uniformly integrating these SWCNT networks throughout the CF fabrics significantly increased electrical conductivity (up to 318 S cm−1), surface area (up to 196 m2 g−1), and in-plane shear properties, all simultaneously. The CNT-infiltrated CFs electrodes exhibited intrinsically high specific energy (2.6–4.2 Wh kg−1) and power (6.0–8.7 kW kg−1) densities in pure 1-ethyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide (EMIM TFSI) electrolyte. Multifunctional structural supercapacitors based on CNT-coated CFs offer a substantial increase in capacitive performance while maintaining the tensile mechanical properties of the as-received CF-based composite. This non-damaging approach to modify CFs with highly graphitic, high surface area nanocarbons provides a new route to structural energy storage systems

Ross-Konno and Endocardial Fibroelastosis Resection After Hybrid Stage I Palliation in Infancy: Successful Staged Left-Ventricular Rehabilitation and Conversion to Biventricular Circulation After Fetal Diagnosis of Aortic Stenosis

We report a patient who presented during fetal life with severe aortic stenosis, left-ventricular dysfunction, and endocardial fibroelastosis (evolving hypoplastic left heart syndrome). Management involved in utero and postnatal balloon aortic valvuloplasty for partial relief of obstruction and early postnatal hybrid stage I palliation until recovery of left-ventricular systolic function had occurred. The infant subsequently had successful conversion to a biventricular circulation by combining resection of endocardial fibroelastosis with single-stage Ross-Konno, aortic arch reconstruction, hybrid takedown, and pulmonary artery reconstruction

Silica aerogel infused hierarchical glass fiber polymer composites

Hierarchical systems can address the matrix-dominated failures of structural fiber polymer composites. Here, a new synergistic hierarchical structure combines conventional structural glass fibers with a bi-continuous silica-based aerogel matrix; both pure-silica and organically-modified silicate aerogels are demonstrated. When infused with an epoxy matrix, this type of hierarchical architecture showed a marked improvement in mechanical properties: without any loss in modulus, both the compressive strength and the interlaminar shear strength increased by up to 27%, relative to the equivalent glass-fiber reinforced epoxy composite baseline. The bi-continuous network modification strategy uses industrially-relevant infusion techniques, at or near room temperature, and retains a similar final composite density (within 2%). The strategy presented here provides a versatile and readily applicable means to improve state-of-the art continuous fiber reinforced composite systems in compression and offers an opportunity to develop a new generation of composite materials