Detecting Multi-Scale Defects in Material Extrusion Additive Manufacturing of Fiber-Reinforced Thermoplastic Composites: A Review of Challenges and Advanced Non-Destructive Testing Techniques

Polymers, Journal Year: 2024, Volume and Issue: 16(21), P. 2986 - 2986

Published: Oct. 24, 2024

Additive manufacturing (AM) defects present significant challenges in fiber-reinforced thermoplastic composites (FRTPCs), directly impacting both their structural and non-structural performance. In structures produced through material extrusion-based AM, specifically fused filament fabrication (FFF), the layer-by-layer deposition can introduce such as porosity (up to 10-15% some cases), delamination, voids, fiber misalignment, incomplete fusion between layers. These compromise mechanical properties, leading reduction of up 30% tensile strength and, cases, 20% fatigue life, severely diminishing composite's overall performance integrity. Conventional non-destructive testing (NDT) techniques often struggle detect multi-scale efficiently, especially when resolution, penetration depth, or heterogeneity pose challenges. This review critically examines FRTPCs, classifying FFF-induced based on morphology, location, size. Advanced NDT techniques, micro-computed tomography (micro-CT), which is capable detecting voids smaller than 10 µm, health monitoring (SHM) systems integrated with self-sensing fibers, are discussed. The role machine-learning (ML) algorithms enhancing sensitivity reliability methods also highlighted, showing that ML integration improve defect detection by 25-30% compared traditional techniques. Finally, potential self-reporting equipped continuous fibers for real-time situ SHM, investigated. By integrating ML-enhanced accuracy efficiency be significantly improved, fostering broader adoption AM aerospace applications enabling production more reliable, defect-minimized FRTPC components.

Language: Английский

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Improvement of carbon fiber oxidation resistance by thin ceramic coating using silica particles

Carbon, Journal Year: 2024, Volume and Issue: 228, P. 119417 - 119417

Published: July 2, 2024

Language: Английский

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Loading rate effect on the shear behavior of the carbon fiber/epoxy interface

Composites Science and Technology, Journal Year: 2024, Volume and Issue: 257, P. 110785 - 110785

Published: Aug. 1, 2024

Language: Английский

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Mechanical Properties of TWILL Carbon Fiber Fabric-Reinforced Single-Layer Thermoplastic Polyamide and Polybutylene Terephthalate-Based Composite Materials Manufactured by Hot Pressing

Materials, Journal Year: 2025, Volume and Issue: 18(2), P. 343 - 343

Published: Jan. 14, 2025

This study investigates carbon fabric-reinforced thermoplastic composites produced via hot pressing, using Polyamide PA6 and Polybutylene Terephthalate (PBT) as matrix materials. These materials are increasingly utilized in the development of lightweight, high-performance, multilayer structures, such aluminum-reinforced laminates, for automotive aerospace applications. The mechanical properties, including tensile strength stiffness, were systematically evaluated under varying loading conditions. PBT-CF composite exhibited a 17% higher stiffness compared to PA6-CF composite, despite low fiber content. highlights critical role uniform distribution enhancing material performance. Slower speeds (1 mm/min) resulted strength, emphasizing influence process parameters on behavior. Cyclic tests showed gradual reduction with increasing strain range, particularly CF-45° configuration. warp weft arrangement fabric contributed structural inhomogeneity but did not significantly affect global properties. findings demonstrate suitability PBT alongside fiber-reinforced thermoplastics, offering new possibilities design advanced tailored

Language: Английский

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Promising Electromagnetic Interference Shielding Materials: Hybrid Fillers Reinforced Bio‐Based Composites

Journal of Applied Polymer Science, Journal Year: 2025, Volume and Issue: unknown

Published: Jan. 22, 2025

ABSTRACT Electromagnetic pollution, also known as electromagnetic interference (EMI) issues, is a growing concern electronic and telecommunication technologies advance. The resulting urgent demand for EMI shielding materials underscores the need development of high‐performance, environmentally friendly materials. Here, we assess impact multiscale carbon‐based hybrid filler on performance polyamide 11/poly(lactic acid) composites. effects amounts (0.5 to 5 wt%) graphene nanoplatelets (GNPs) multiwalled carbon nanotube (MWCNT) nanofillers in fiber (CF)/GNP CF/MWCNT‐reinforced composites were comparatively investigated. fabricated through melt blending/compression molding subsequently characterized terms morphological, length, electrical properties, effectiveness (EMI SE). Morphological imaging revealed good adhesion between fillers matrix, indicating favorable interaction. length analysis demonstrated that lengths longer CF/GNP than CF/MWCNT. SE measurements showed synergistic X Ku bands. highest values at 10 GHz 16 20CF‐5GNP composite 34 40 dB, respectively.

Language: Английский

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Recent advances of Fiber-reinforced polymer composites for defense innovations

Results in Chemistry, Journal Year: 2025, Volume and Issue: unknown, P. 102199 - 102199

Published: March 1, 2025

Language: Английский

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Carbon Fiber Reinforced Thermoplastics: From Materials to Manufacturing and Applications

Advanced Materials, Journal Year: 2025, Volume and Issue: unknown

Published: April 22, 2025

Abstract Carbon fiber reinforced thermoplastics (CFRTs) have witnessed a resurgence in recent times since their first industrial use over five decades ago, with revitalized interest from aerospace companies and other key sectors including energy automotive sectors. CFRTs are increasingly gaining footholds high volume rapid manufacturing nonaerospace owing to inherent recyclability. However, there has been lack of contemporary critical review on this topic so far. This work aims the advances emphasis performance thermoplastics. Both continuous discontinuous forms tape, organosheet short/long architectures discussed, processing postprocessing methods reviewed, state‐of‐the‐art welding techniques. Typical applications industry examined, fuselage, pressure vessel, components. Finally, insights provided into ongoing challenges, future development, roadmap for expediting development high‐performance CFRTs.

Language: Английский

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Ultrahigh strength and modulus of polyimide-carbon nanotube based carbon and graphitic fibers with superior electrical and thermal conductivities for advanced composite applications

Composites Part B Engineering, Journal Year: 2022, Volume and Issue: 247, P. 110342 - 110342

Published: Oct. 7, 2022

Development of carbon fibers (CFs) with high strength and modulus for structural applications in CF-reinforced polymer (CFRP) industry has been a challenge. Herein, we propose method manufacturing highly oriented polymer–carbon nanotube (CNT) composite having (4.8 ± 0.2 GPa), (390 48 electrical conductivity (5.75 0.84 MS m-1) by liquid crystalline wet-spinning process. The use chlorosulfonic acid (CSA) as solvent CNTs polyimide (PI) promotes dispersion enables the production high-performance fibers. In addition, functional groups PI improve interfacial shear epoxy resin without sizing additives 72% compared to that CNT Carbonization graphitization an optimal ratio (30%) cause significant improvement their mechanical (tensile strength; 6.21 0.3 GPa modulus; 701 47 GPa) thermal properties (496 38 W m−1 K−1) reducing voids improving orientation. We believe polymer–CNT composites CFs would be next-generation aerospace defense industry.

Language: Английский

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Enhanced mechanical and interfacial performances of carbon fiber reinforced composites with low percentage of amine functionalized graphene

Polymer Composites, Journal Year: 2024, Volume and Issue: 45(15), P. 13772 - 13790

Published: July 3, 2024

Abstract This paper reports improvement in the tensile, flexural and interlaminar shear strength (ILSS) properties of ADG‐NH 2 /Epoxy/CFRP composites at low filler content. Five symmetrical CFRP composite laminates were prepared through wet layup process assisted by vacuum bagging technique with varying wt% proportions (0.25, 0.5, 0.75 1) /Epoxy. Tensile tests, short beam test tests carried out as per ASTM D3039, D2344 790‐10 respectively to assess effect functionalized nano additives on their mechanical properties. The variation ILSS studied for temperatures (room temperature, 35, 50, 75, 85, & 100°C each type /Epoxy (neat, 0.25, 1)) composites. was enhanced up ∼27% 0.5 reinforced room temperature but reduced higher concentrations (0.75 1 wt%). It observed that gradual variations w.r.t temperature. But an increment all Form results, it has been recorded is, elastic modulus ∼18%, ultimate tensile ∼21%, % elongation break by∼19% toughness by∼28% graphene additive compared neat epoxy laminates. Results also show augmentation Max load ∼24%, ∼33%, ∼43%, strain ∼26% Fractographic studies fractured surface using SEM analyses shows better adhesion mechanisms which supports addition amine laminate. Highlights Reinforcement (ADG‐NH ) matrix incorporation carbon fibers enhance interfacial Evaluation effects Improvements a percentage (0.5 wt%) Use aerospace grade resin further use industry applications.

Language: Английский

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Augmenting the fracture toughness and structural health monitoring capabilities in Kevlar/epoxy composites using carbon nanotubes

Engineering Fracture Mechanics, Journal Year: 2024, Volume and Issue: 297, P. 109877 - 109877

Published: Jan. 17, 2024

Language: Английский

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