Bronwyn Fox

Toughening of a Carbon-Fibre Composite Using Electrospun Poly(Hydroxyether of Bisphenol A) Nanofibrous Membranes Through Inverse Phase Separation and Inter-Domain Etherification

The interlaminar toughening of a carbon fibre reinforced composite by interleaving a thin layer (~20 microns) of poly(hydroxyether of bisphenol A) (phenoxy) nanofibres was explored in this work. Nanofibres, free of defect and averaging several hundred nanometres, were produced by electrospinning directly onto a pre-impregnated carbon fibre material (Toray G83C) at various concentrations between 0.5 wt % and 2 wt %. During curing at 150 °C, phenoxy diffuses through the epoxy resin to form a semi interpenetrating network with an inverse phase type of morphology where the epoxy became the co-continuous phase with a nodular morphology. This type of morphology improved the fracture toughness in mode I (opening failure) and mode II (in-plane shear failure) by up to 150% and 30%, respectively. Interlaminar shear stress test results showed that the interleaving did not negatively affect the effective in-plane strength of the composites. Furthermore, there was some evidence from DMTA and FT-IR analysis to suggest that inter-domain etherification between the residual epoxide groups with the pendant hydroxyl groups of the phenoxy occurred, also leading to an increase in glass transition temperature (~7.5 °C).

Morphology-property relationships in ABS/PET blends. I. Compositional effects

Novel blends of PET and ABS were prepared by extrusion and injection molding. DSC and DMTA studies show that PET and ABS are immiscible and that the blends consist of four phases : SAN, grafted polybutadiene, amorphous PET, and minor amounts of crystalline PET. The morphology was investigated by transmission electron microscopy on OsO 4 -stained and unstained sections and by scanning electron microscopy of alkali- and solvent-etched surfaces. These techniques reveal that the two major domains, SAN and amorphous PET, interpenetrate and are cocontinuous over the compositional range of 30-70 wt % PET. The yield stress and flexural modulus increase in an almost linear fashion as the weight fraction of PET in the blend is increased. In contrast, the notched Izod impact energy passes through a maximum and the Dart impact energy shows a step transition at 50 wt % PET. SEM studies of the Izod fracture surfaces exhibit considerable plastic deformation in both domains when the specimens are tough, indicating that both phases participate in the toughening process.

Dynamic Prediction Models and Optimization of Polyacrylonitrile (PAN) Stabilization Processes for Production of Carbon Fiber

Thermal stabilization process of polyacrylonitrile (PAN) is the slowest and the most energy-consuming step in carbon fiber production. As such, in industrial production of carbon fiber, this step is considered as a major bottleneck in the whole process. Stabilization process parameters are usually many in number and highly constrained, leading to high uncertainty. The goal of this paper is to study and analyze the carbon fiber thermal stabilization process through presenting several effective dynamic models for the prediction of the process. The key point with using dynamic models is that using an evolutionary search technique, the heat of reaction can be optimized. The employed components of the study are Levenberg-Marquardt algorithm (LMA)-neural network (LMA-NN), Gauss-Newton (GN)-curve fitting, Taylor polynomial method, and a genetic algorithm. The results show that the procedure can effectively optimize a given PAN fiber heat of reaction based on determining the proper values of heating ramp and temperature.

Crack damage in polymers and composites : a review

Polymer-based materials are extensively used in various applications such as aircrafts, civilian structures, oil and gas platforms and electronics. They are, however, inherently damage prone and over time, the formation of cracks and microscopic damages influences the thermo-mechanical and electrical properties, which eventually results in the total failure of the materials. This paper provides an overview of the principal causes of cracking in polymer and composites and summarizes the recent progress in the development of non-destructive techniques in crack detection. Furthermore, recent progress in the development of bio-inspired self-healing methods in autonomic repair is discussed.

Individual dispersion of carbon nanotubes in epoxy via a novel dispersion–curing approach using ionic liquids

The effective dispersion of carbon nanotubes (CNTs) in a thermoset was achieved using ionic liquid as the dispersion-curing agent. We preferentially dispersed multiwalled carbon nanotubes (MWCNTs) down to individual tube levels in epoxy resin. Here the dispersion is ruled by the depletion of physical bundles within the MWCNT networks, for which molecular ordering of ionic liquids is considered responsible. The quantitative analyses using ultra small angle X-ray scattering (USAXS) confirmed the dispersion of individual MWCNTs in the matrix. The distance between the dispersed nanotubes was calculated at different nanotube loadings using the power law fitting of the USAXS data. The fine dispersion and subsequent curing, both controlled by ionic liquid, lead to composites with substantially enhanced fracture mechanical and thermomechanical properties with no reduction in thermal properties. Merging processing techniques of nanocomposites with ionic liquid for efficient dispersion of nanotubes and preferential curing of thermosets facilitates the development of new, high performance materials.

Manufacturing Influence on the Delamination Fracture Behavior of the T800H/3900-2 Carbon Fiber Reinforced Polymer Composites

‘Torayca’ T800H/3900-2 is the first material qualified on Boeing Material Specification (BMS 8-276) which utilizes the thermoplastic-particulate interlayer toughening technology. Two manufacturing processes, the autoclave process and the fast heating rated Quickstep™ process, were employed to cure this material. The Quickstep process is a unique composite production technology which utilizes the fast heat transfer rate of fluid to heat and cure polymer composite components. The manufacturing influence on the mode I delamination fracture toughness of laminates was investigated by performing double cantilever beam tests. The composite specimens fabricated by two processes exhibited dissimilar delamination resistance curves (R-curves) under mode I loading. The initial value of fracture toughness G IC–INIT was 564 J/m2 for the autoclave specimens and 527 J/m2 for the Quickstep specimens. However, the average propagation fracture toughness G IC–PROP was 783 J/m2 for the Quickstep specimens, which was 2.6 times of that for the autoclave specimens. The mechanism of fracture occurred during delamination was studied under scanning electron microscope (SEM). Three types of fracture were observed: the interlayer fracture, the interface fracture, and the intralaminar fracture. These three types of fracture played different roles in affecting the delamination resistance curves during the crack growth. More fiber bridging was found in the process of delamination for the Quickstep specimens. Better fiber/matrix adhesion was found in the Quickstep specimens by conducting indentation-debond tests.

A novel approach to functionalise pristine unsized carbon fibre using in situ generated diazonium species to enhance interfacial shear strength

Complex molecules have been successfully grafted onto the surface of unsized carbon fibre, a heterogeneous material which is a challenge to functionalise. The in situ generation of highly reactive phenyldiazo-species from their corresponding anilines was employed to achieve this task. The success of an initial proof-of-concept study (bearing a nitro moiety) supported by X-ray Photoelectron Spectroscopy (XPS) and physical characterisation, led to the design and synthesis of a more complex compound possessing a pendant amine moiety which could theoretically react with an epoxide based resin. After attachment to unsized oxidised fibres, analysis by XPS of the resulting fibres (fluorine used as an XPS tag) indicated a marked difference in functionalisation success which was attributed to steric factors, shown to be critical in influencing the attachment of the phenyldiazo-intermediate to the carbon fibre surface. Analysis of key fibre performance parameters of these fibres showed no change in elastic modulus, strength, surface topography or microscopic roughness when compared to the control unsized oxidised fibres. The functionalised fibres did however show a large increase in coefficient of friction. Single fibre fragmentation tests indicated a marked increase in interfacial shear strength, which was attributed to the pendent amine functionalities interacting with the epoxy resin.

Enhanced thermal stability and lifetime of epoxy nanocomposites using covalently functionalized clay: experimental and modelling

The present work aims at finding a relationship between kinetic models of thermal degradation process with the physiochemical structure of epoxy–clay nanocomposites in order to understand its service temperature. In this work, two different types of modified clays, including clay modified with (3-aminopropyl)triethoxysilane (APTES) and a commercial organoclay, were covalently and non-covalently incorporated into epoxy matrix, respectively. The effect of different concentrations of silanized clay on thermal behaviour of epoxy nanocomposites were first investigated in order to choose the optimum clay concentration. Afterwards, thermal characteristics of the degradation process of epoxy nanocomposites were obtained by TGA analysis and the results were employed to determine the kinetic parameters using model-free isoconversional and model-fitting methods. The obtained kinetic parameters were used to model the entire degradation process. The results showed that the incorporation of the different modified clay into epoxy matrix change the mathematical model of the degradation process, associating with different orientations of clay into epoxy matrix confirming by XRD results. The obtained models for each epoxy nanocomposite systems were used to investigate the dependence of degradation rate and degradation time on temperature and conversion degree. Our results provide an explanation as to how the life time of epoxy and its nanocomposites change in a wide range of operating temperatures as a result of their structural changes.

Overcoming Interfacial Affinity Issues in Natural Fiber Reinforced Polylactide Biocomposites by Surface Adsorption of Amphiphilic Block Copolymers

This work demonstrates that the interfacial properties in a natural fiber reinforced polylactide bio-composite can be tailored through surface adsorption of amphiphilic and biodegradable poly (ethylene glycol)-b-poly(l-lactide) (PEG-PLLA) block copolymers. The deposition from solvent solution of PEG-PLLA copolymers onto the fibrous substrate induced distinct mechanisms of molecular organization at the cellulosic interface, which are correlated to the hydrophobic/hydrophilic ratios and the type of solvent used. The findings of the study evidenced that the performance of the corresponding biocomposites with polylactide were effectively enhanced by using these copolymers as interfacial coupling agents. During the fabrication stage, diffusion of the polylactide in the melt induced a change in the environment surrounding block copolymers which became hydrophobic. It is proposed that molecular reorganization of the block copolymers at the interface occurred, which favored the interactions with both the hydrophilic fibers and hydrophobic polylactide matrix. The strong interactions such as intra- and intermolecular hydrogen bonds formed across the fiber-matrix interface can be accounted for the enhancement in properties displayed by the biocomposites. Although the results reported here are confined, this concept is unique as it shows that by tuning the amphiphilicity and the type of building blocks, it is possible to control the surface properties of the substrate by self-assembly and disassembly of the amphiphiles for functional materials.

Characterization and Analysis of Delamination Fracture and Nanocreep Properties in Carbon Epoxy Composites Manufactured by Different Processes

Delamination resistance and nanocreep properties of 2/2 twill weave carbon epoxy composites manufactured by hot press, autoclave, and Quickstep™process are characterized and analyzed. Quickstep is a fluid filled, balanced pressure heated floating mold technology, which is recently developed in Perth, Western Australia for the manufacture of advanced composite components. Mode I and Mode II interlaminar fracture toughness tests, and nanoindentation creep tests on matrix materials show that the fast ramp rate of the Quickstep process provides mechanical properties comparable to that of autoclave at a lower cost for composite manufacturing. Low viscosity during ramping process and good fiber wetting are believed to be the reasons that this process produces composites with high delamination and creep-resistant properties. Nanocreep properties are analyzed using a Kelvin–Voigt model.