Characterisation of natural fibres for sustainable discontinuous fibre composite materials

Growing environmental concerns and stringent waste-flow regulations make the development of sustainable composites a current industrial necessity. Natural fibre reinforcements are derived from renewable resources and are both cheap and biodegradable. When they are produced using eco-friendly, low hazard processes, then they can be considered as a sustainable source of fibrous reinforcement. Furthermore, their specific mechanical properties are comparable to commonly used, non-environmentally friendly glass-fibres. In this study, four types of abundant natural fibres (jute, kenaf, curaua, and flax) are investigated as naturally-derived constituents for high performance composites. Physical, thermal, and mechanical properties of the natural fibres are examined to evaluate their suitability as discontinuous reinforcements whilst also generating a database for material selection. Single fibre tensile and microbond tests were performed to obtain stiffness, strength, elongation, and interfacial shear strength of the fibres with an epoxy resin. Moreover, the critical fibre lengths of the natural fibres, which are important for defining the mechanical performances of discontinuous and short fibre composites, were calculated for the purpose of possible processing of highly aligned discontinuous fibres. This study is informative regarding the selection of the type and length of natural fibres for the subsequent production of discontinuous fibre composites

Pseudo-Ductile Behaviour in Fibre Reinforced Thermoplastic Angle-ply Composites

Pseudo-ductile behaviour has previously been demonstrated in a [±45n]s carbon fibre composite via fibre rotation. To further develop the pseudo-ductile response, the high strain properties of the matrix should be considered to avoid strain localisation and potentially exploit strain-hardening in an amorphous thermoplastic matrix. For the first time, polycarbonate, a high strain-to-failure matrix is utilised in a pseudo-ductile composite design and compared to a high performance thermoset fibre composite containing an epoxy resin. The use of polycarbonate leads to enhanced pseudo-ductile strain (49%), longitudinal strength (24%) and apparent in-plane shear strength (26%), albeit with a reduction in elastic modulus (26%), shear chord modulus (22%) and yield strength (26%)

Improving Dispersion of Recycled Discontinuous Carbon Fibres to Increase Fibre Throughput in the HiPerDiF Process

In order to increase the material throughput of aligned discontinuous fibre composites using technologies such as HiPerDiF, stability of the carbon fibres in an aqueous solution needs to be achieved. Subsequently, a range of surfactants, typically employed to disperse carbon-based materials, have been assessed to determine the most appropriate for use in this regard. The optimum stability of the discontinuous fibres was observed when using the anionic surfactant, sodium dodecylbenzene sulphonate, which was superior to a range of other non-ionic and anionic surfactants, and single-fibre fragmentation demonstrated that the employment of sodium dodecylbenzene sulphonate did not affect the interfacial adhesion between fibres. Rheometry was used to complement the study, to understand the potential mechanisms of the improved stability of discontinuous fibres in aqueous suspension, and it led to the understanding that the increased viscosity was a significant factor. For the shear rates employed, fibre deformation was neither expected nor observed

Multi-Functional Carbon Fibre Composites using Carbon Nanotubes as an Alternative to Polymer Sizing

Carbon fibre reinforced polymers (CFRP) were introduced to the aerospace, automobile and civil engineering industries for their high strength and low weight. A key feature of CFRP is the polymer sizing - a coating applied to the surface of the carbon fibres to assist handling, improve the interfacial adhesion between fibre and polymer matrix and allow this matrix to wet-out the carbon fibres. In this paper, we introduce an alternative material to the polymer sizing, namely carbon nanotubes (CNTs) on the carbon fibres, which in addition imparts electrical and thermal functionality. High quality CNTs are grown at a high density as a result of a 35 nm aluminium interlayer which has previously been shown to minimise diffusion of the catalyst in the carbon fibre substrate. A CNT modified-CFRP show 300%, 450% and 230% improvements in the electrical conductivity on the ‘surface’, ‘through-thickness’ and ‘volume’ directions, respectively. Furthermore, through-thickness thermal conductivity calculations reveal a 107% increase. These improvements suggest the potential of a direct replacement for lightning strike solutions and to enhance the efficiency of current de-icing solutions employed in the aerospace industry

Quasi-Isotropic and Pseudo-Ductile Highly Aligned Discontinuous Fibre Composites Manufactured with the HiPerDiF (High Performance Discontinuous Fibre) Technology

Conventional composite materials reinforced with continuous fibres display high specific strength but have a number of drawbacks including: the elastic-brittle behaviour, difficulties in producing defect-free components of complex shape with high-volume automated manufacturing processes, and inherent lack of recyclability. Highly aligned, discontinuous fibre-reinforced composites (ADFRCs) are truly beneficial for mass production applications, with the potential to offer better formability and comparable mechanical properties with continuous fibre-reinforced composites. In previous publications, the High Performance Discontinuous Fibre (HiPerDiF) technology has been shown to offer the possibility to intimately hybridise different types of fibres, to achieve pseudo-ductile tensile behaviour, and remanufacture reclaimed fibres into high-performance recycled composites. However, to date, the work has been conducted with unidirectional (UD) laminates, which is of limited interest in engineering applications with mechanical stresses acting across many directions; this paper reports, for the first time, the mechanical behaviour of quasi-isotropic (QI) ADFRCs. When compared with randomly-oriented discontinuous fibre composites (RODFRCs), QI ADFRCs offer enhanced stiffness (+26%) and strength (+77%) with higher consistency, i.e., a reduction of the coefficient of variance from the 25% of RODFRCs to the 6% of ADFRCs. Furthermore, hybrid QI ADFRCs retain the pseudo-ductility tensile behaviour previously observed in unidirectional (UD) lay-up