Graphene reinforced carbon fibers
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99 GENERAL AND MISCELLANEOUS↗
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Results for “REINFORCING FIBER”
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Mechanical degradation of duplex SiC-fiber reinforced SiC matrix composite tubes under a controlled high-temperature steam environment
This paper describes results from the mechanical evaluation of unirradiated SiC fiber–reinforced SiC matrix composite tubes under a controlled high-temperature steam environment. The experiments were aimed at identifying key material degradation behavior under environments relevant to loss-of-coolant accidents of light water reactors. Mechanical tests of the SiC composite tubes at 1000 °C under steam and inert environments were conducted using a unique test capability. Further, the material tested was a duplex tube with a thick monolithic SiC layer on the outer surface. The tubes were subjected to preloading at ~100 MPa in tension before exposure to high-temperature steam with up to 75% of the preload at a constant displacement. In the presence of matrix cracks, the steam exposure caused embrittlement of the SiC composite tubes and failure at a stress level below the pretest stress. The material degradation was explained by a fiber oxidation model, which can be applied to various SiC cladding concepts. The embrittlement could be a limiting factor for using SiC cladding subjected to loss-of-coolant accident conditions.
36 MATERIALS SCIENCE↗
Functionally Designed Ultra-Lightweight Carbon Fiber Reinforced Thermoplastic Composites Door Assembly (Final Scientific/Technical Report)
This is the final technical report for a project that developed an ultra-lightweight carbon fiber reinforced thermoplastics composite door assembly for a mid-size SUV. The project was able achieve a weight reduction of at least 42.5% while maintaining or exceeding the fit, function, safety, stiffness, and crash performance requirements of the current baseline door. Additionally, the target cost was set at less than $5 per pound of weight saved. To accomplish these goals, the project team employed a systems approach that involves redesigning the door assembly, exploring novel materials, optimizing the design, and utilizing advanced manufacturing technologies.
42 ENGINEERING↗
Empirical Characterization and Modeling of Cohesive – to – Adhesive Shear Fracture Mode Transition due to Increased Adhesive Layer Thicknesses of Fiber Reinforced Composite Single – Lap Joints
Here, to ensure a strong adhesive bond, most standards and adhesive manufacturers specify a maximum adhesive gap of 1 mm when bonding fiber reinforced composite structures. In manufacturing large components, such as joining two halves of wind turbine blades, meeting this gap tolerance specification is impractical; gaps larger than 10 mm are common in large adhesively bonded composite structures using state-of-the-art manufacturing techniques. Currently, there is a lack of fundamental understanding of the failure mechanics of adhesive gaps larger than 3 mm. To create such understanding, glass fiber - acrylic thermoplastic composite panels bonded using different epoxy adhesives within single-lap joint samples with adhesive thicknesses of 0.1 mm, 0.3 mm, 1 mm, 3 mm, 5 mm, and 10 mm were sheared to failure. A transition from cohesive to adhesive failure was observed to occur about 1 mm to 3 mm joint thicknesses. Plotting the shear stress normalized by the ratio of the joint width to thickness as a function of the joint thickness normalized by the joint length is shown to result in the ability to fit simple empirically derived models of the cohesive-to-adhesive failure transition, regardless of the adhesive. Furthermore, using these normalized variables, all the observed cohesively failed specimens collapse to a single master curve, as do the adhesively failed specimens.
36 MATERIALS SCIENCE↗
Resin transfer molding systems and control logic for manufacturing fiber-reinforced composite parts
Presented are manufacturing control systems for fabricating composite-material structures, methods for making/operating such systems, and resin transfer molding techniques for ameliorating race-tracking effects in fiber-reinforced polymer panels. A method for forming a composite-material construction includes confirming, via a system electronic control unit (ECU), that a fiber-based preform is placed in a mold cavity and that opposing mold segments of the molding apparatus are sealed together. A filler, such as a compressible bladder, a cluster of spring-biased pins, or a spray-chopped fiber bed, is introduced into a void between the fiber-based preform and a tool face of one mold segment to thereby eliminate an unwanted resin race track. The system ECU commands a resin pump to inject resin through a primary gate of the molding apparatus and into the mold cavity to thereby impregnate the fiber-based preform with the resin. One or more vents operate to evacuate air from the mold.
Rodgers, William R.↗
An Advanced Meso-Scale Peridynamic Modeling Technology using High-Performance Computing for Cost-Effective Product Design and Testing of Carbon Fiber Reinforced Polymer Composites in Light-weight Vehicles
We study a peridynamic composite modeling technology based on the discontinuous Galerkin finite element method, implemented in the commercial LS-DYNA software, for modeling and prediction of failure in carbon fiber reinforced polymer composites. The proposed technology is developed for the material failure analysis at the meso-scale, which provides the prevailing fiber-matrix interaction mechanism, without adoption of the representative volume element method and thus avoiding complicated numerical calibration procedures. Three types of experimental tests—in-plane coupon test, out-of-plane coupon test, and a component crash test—are simulated in a high-performance computing environment to assess the performance of the proposed peridynamic composite modeling technology.
36 MATERIALS SCIENCE↗
Vertical z-axis discontinuous carbon fibers for improved lightning strike performance of continuous fiber-reinforced polymer composites
Effective lightning strike protection for critical aerospace and wind applications requires high electrical conductivity to dissipate current efficiently. However, polymer matrix composites face a challenge due to their inherently insulating nature. While conventional carbon fiber-reinforced composites (CFRP) exhibit electrical conductivity in the planar direction, achieving through-thickness conductivity remains an ongoing challenge. In this work, we have undertaken the fabrication of CFRP interleaved with vertically oriented carbon fibers (Z-fiber) to impart higher electrical conductivity along the thickness direction. Two Z-fiber composite variations are prepared: Z-1 with a single layer of Z-fiber and Z-5 with five interleaved layers and compared with no Z-fiber layer (Z-0) composite. The composite panels were subjected to lab-scale lightning strike tests with a current magnitude of 100 kA. To emulate real-world service conditions, an aerospace-grade paint coating was applied to the composite laminates. Comparative analysis shows Z-1 reduces damage diameter to ∼22 mm compared to Z-0 (∼26 mm), while Z-5 exhibits the least damage (∼16.7 mm), confirmed by optical microscopy. Z-5 demonstrates nine times higher through-thickness electrical conductivity than Z-0, reducing electrical anisotropy substantially. Thermal-electric finite element damage modeling predicts surface damage within 6% of experimental values for both Z-0 and Z-5 composites. Flexural tests post-lightning reveal Z-5 retains 66% flexural strength and 86% modulus, significantly better than Z-0, which retains less than 40% for both properties. This study highlights the efficacy of Z-fiber composites in lightning strike protection, offering improved through-thickness conductivity and mechanical property retention.
36 MATERIALS SCIENCE↗
Joining of Thermoset Carbon Fiber Reinforced Polymer and AZ31 Magnesium Alloy Sheet Via Friction Stir Interlocking
A new technique called friction stir interlocking (FSI) was applied for lap-joining of AZ31 magnesium sheet and thermoset carbon fiber reinforced polymer (TS-CFRP) sheet. Instead of directly joining AZ31 and TS-CFRP, a series of magnesium interlocks were used to friction stir weld with AZ31 sheet to enable joining with TS-CFRP. Microstructural characterization of joint cross sections showed that a tool rotation rate of 800 rpm produced incomplete mixing of magnesium interlocks and the top AZ31 sheet, while 1200 rpm achieved sufficient material mixing to avoid unwelded regions. Mechanical property characterization showed that AZ31/TS-CFRP dissimilar joints failed through the magnesium interlock shanks during lap shear tensile testing, with a maximum normalized joint strength reaching ~100 MPa.
Wang, Tianhao↗
3D printed carbon fiber reinforced carbon as an energy efficient alternative to graphite for EFAS tooling
As Electric Field Assisted Sintering (EFAS) gains more industrial acceptance and use, it becomes more important to develop more efficient means to implement this technology. To this aim, 3D printed continuous carbon fiber reinforced carbon (CCC) was manufactured and fabricated into tooling for EFAS systems as an alternative to traditional graphite tooling. The impact of fiber orientation on the thermal and electrical properties of the CCC was characterized. Sample material was sintered in Tokai G535 graphite tooling, under common processing conditions and compared with CCC tooling. There was nearly 50 % energy savings compared to graphite while maintaining equivalent sample density and microstructure plus keeping ram temperatures 39 % cooler. This is due to spatial control of generated heat and thermal diffusivity within the molds, by means of fiber orientation anisotropy. Finite element modeling of the tooling design supported the experimental results as well as displays the effect of optimization of this 3D printed CCC material.
36 MATERIALS SCIENCE↗
Tech Sheet for Isotropic Fiber Reinforced Polymer
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Isotropic Fiber Reinforced Polymer Additive Manufa↗
Recyclable Cellulose Fiber Reinforced Vitrimer Composite
Vitrimer is an innovative class of polymeric materials which demonstrates traditional thermoset-like mechanical and chemical resilience while still being able to flow on demand like a traditional thermoplastic through covalently adaptive dynamic linkages. Herein, high-performance cellulose fiber reinforced vitrimer composites are developed using an epoxy-based vitrimer and natural cellulose paper. The reinforced vitrimer composite was fabricated by impregnating the porous structure of cellulose paper with two curable monomers, followed by in-situ polymerization of the monomers inside the fibrous scaffold. The introduction of hydroxyl group present on the cellulosic framework assisted in a faster topological rearrangement of the crosslinked matrix through transesterification exchange reaction, thus imparting various sought-after properties like shape recovery and recyclability via simple thermal reprocessing. Moreover, the reinforced vitrimer composite exhibits superior tensile properties as high as 90 MPa with 15-25 volume% vitrimer loading due to the interfacial adhesion via ester exchange reaction between the epoxy matrix and functionalities on the cellulosic fibers. Noteworthily, the key ingredients of the resulting composite (i.e., epoxy-based vitrimer and cellulose fibers) can be comfortably recycled without using aggressive chemical treatment, enabling composite to be easily recycled or disposed of at the end of service life and assist in reducing the subsequent manufacturing cost. This study would shed light on the development of a recyclable polymer composite with exceptional mechanical properties while simultaneously demonstrating self-healing and shape memory capabilities.
Rohewal, Sargun Singh↗
Nondestructive Evaluation of Carbon Fiber Reinforced Polymers
The American Society of Mechanical Engineers Boiler and Pressure Vessel Code requires repair and replacement of safety-related piping materials to meet the original Construction Code; however, no construction criteria currently exist for carbon fiber reinforced polymer (CFRP) materials in the nuclear industry. Although nondestructive examination (NDE) techniques for cast and wrought ferritic and austenitic steels are well established, licensees are increasingly deploying novel materials such as CFRP for which assessment of the use of NDE is required, as the inspectability of such materials and the influence of manufacturing processes on inspectability remain insufficiently understood. To address these gaps, Pacific Northwest National Laboratory (PNNL) evaluated the fabrication of several CFRP repair mockups and the effectiveness of NDE methods to support regulatory review of CFRP repairs in nuclear power plant applications. Representative flat-plate mockups containing realistic fabrication defects were manufactured and inspected using manual and automated tap testing, dynamic response spectroscopy (DRS), and ultrasonic testing (UT). The study identified significant fabrication variability, particularly in controlling defect size and epoxy thickness, which strongly influenced defect detectability by NDE methods. Tap testing was effective for shallow defects in thin epoxy configurations but unreliable for thicker repairs and deeper flaws. DRS demonstrated higher sensitivity to dry spots but produced unconfirmed indications for thicker plates, requiring further validation. Conventional UT, particularly at 1.0 MHz, showed the strongest overall capability for detecting a range of defects, although performance degraded with increasing repair thickness and complexity. The results highlight the need to better define critical defect sizes, develop reliable mockup fabrication methods, and validate NDE methods needed to support CFRP repairs.
36 MATERIALS SCIENCE↗
Thickness threshold study of polyaniline-based lightning strike protection coating for carbon/glass fiber reinforced polymer composites
Different polyaniline (PANI) based lightning strike protection (LSP) coating thicknesses were tested against simulated lightning strike tests to evaluate the threshold thickness of the coating. A series of lightning strike tests were performed on carbon/glass fiber reinforced polymer (CFRP/GFRP) composites subjected to simulated lightning currents ranging from 40 to 100 kA. Five LSP-coated specimens were considered herein: two CFRP and three GFRP composites. A minimum of ~ 345 μm thick PANI-based LSP coating on CFRP and GFRP composites under a 40 kA peak current retained 83 % and 100 % residual strength, respectively. Additionally, GFRP specimens tested against 60 and 100 kA peak currents exhibited 100 % residual strength. Finally, this study proposes that a PANI-based LSP coating is suitable for protecting GFRP composites, while the careful design is necessary for CFRP composites to avoid any catastrophic failure.
36 MATERIALS SCIENCE↗
Post-Deployment Characterization of Glass Fiber-Reinforced Thermoset and Thermoplastic Composite Tidal Turbine Blades: Preprint
In 2021, the National Renewable Energy Laboratory (NREL) supported Verdant Power with the most successful tidal energy deployment in U.S. history. Three of their tidal turbines were deployed as part of the Roosevelt Island Tidal Energy project. Initially, the three rotors were manufactured from glass fiber-reinforced epoxy composites. Midway through the deployment, one rotor was replaced with one manufactured at NREL. Instead, it was infused with a novel, infusible thermoplastic resin system. Since the deployment, one epoxy rotor and one thermoplastic rotor were returned to NREL for continued materials and manufacturing research. The two rotors underwent full-scale structural testing before being sectioned and cut into specimens for a variety of manufacturing quality tests, thermos-mechanical characterization, and evaluation of material performance in marine environments, to understand the key differences between the fiberglass reinforced epoxy and Elium composites used for the respective rotors. Matrix burnoff tests showed that the Elium blades had a considerably higher fiber volume fraction compared to the epoxy blades (61% vs. 49%). Environmental aging of the specimens showed that the epoxy laminates absorbed more water over the conditioning period, however, it was determined that the Elium laminates had higher diffusion coefficients, so initially absorbed water faster. Finally, one full epoxy blade and one full Elium blade were conditioned at ambient temperatures for up to 11 months, while taking periodic mass measurements. The datasets were extrapolated out to assume a full 20 year operational life span and it was determined that the blades would not reach full saturation during that time span.
composite manufacturing↗
Post-Deployment Characterization of Glass Fiber-Reinforced Thermoset and Thermoplastic Composite Tidal Turbine Blades
In 2021, the National Renewable Energy Laboratory (NREL) supported Verdant Power with the most successful tidal energy deployment in U.S. history. Three of their Gen5d 5 m turbines were deployed as part of the Roosevelt Island Tidal Energy project. Initially, the three deployed rotors were manufactured from glass fiber-reinforced epoxy composites. Midway through the deployment, one rotor was replaced with one manufactured at NREL. The new rotor utilized a novel infusible thermoplastic resin system (Elium from Arkema). Since the deployment, one epoxy rotor and one thermoplastic rotor were returned to NREL for continued materials and manufacturing research. The two rotors underwent full-scale structural testing before being sectioned and cut into specimens for a variety of manufacturing quality tests, thermomechanical characterization, and evaluation of material performance in marine environments to understand the key differences between the fiberglass-reinforced epoxy and Elium composites used for the respective rotors. Matrix burn-off tests showed that the Elium blades had a considerably higher fiber volume fraction compared to the epoxy blades (61% vs. 49%). Environmental aging of the specimens showed that the epoxy laminates absorbed more water over the conditioning period; however, it was determined that the Elium laminates had higher diffusion coefficients, so they initially absorbed water faster. Finally, one full epoxy blade and one full Elium blade were conditioned at ambient temperatures for up to 11 months, while periodic mass measurements were taken. The datasets were extrapolated to assume a full 20-year operational life span, and it was determined that the blades would not reach full saturation during that time span.
composite manufacturing↗
Post-Deployment Characterization of Glass Fiber-Reinforced Thermoset and Thermoplastic Composite Tidal Turbine Blades
In 2021, the National Renewable Energy Laboratory (NREL) supported Verdant Power with the most successful tidal energy deployment in U.S. history. Three of their Gen5d 5 m turbines were deployed as part of the Roosevelt Island Tidal Energy project. Initially, the three rotors initially deployed were manufactured from glass fiber-reinforced epoxy composites. Midway through the deployment, one rotor was replaced with one manufactured at NREL. The new rotor utilized a novel infusible thermoplastic resin system. Since the deployment, one epoxy rotor and one thermoplastic rotor were returned to NREL for continued materials and manufacturing research. The two rotors underwent full-scale structural testing before being sectioned and cut into specimens for a variety of manufacturing quality tests, thermomechanical characterization, and evaluation of material performance in marine environments to understand the key differences between the fiberglass-reinforced epoxy and Elium composites used for the respective rotors. Matrix burn-off tests showed that the Elium blades had a considerably higher fiber volume fraction compared to the epoxy blades (61% vs. 49%). Environmental aging of the specimens showed that the epoxy laminates absorbed more water over the conditioning period; however, it was determined that the Elium laminates had higher diffusion coefficients, so they initially absorbed water faster. Finally, one full epoxy blade and one full Elium blade were conditioned at ambient temperatures for up to 11 months, while periodic mass measurements were taken. The datasets were extrapolated to assume a full 20-year operational life span, and it was determined that the blades would not reach full saturation during that time span.
composite manufacturing↗
Integrated TBC/EBC for SiC Fiber Reinforced SiC Matrix Composites for Next Generation Gas Turbines (Final Report)
In this ambitious project, a significant challenge preventing widespread use of ceramic matrix composites in hot section components of gas power generating turbines was addressed. Hot section components made from SiC fiber reinforced SiC matrix composites (SiC/SiC composites), have the potential to achieve a combined cycle energy efficiency of above 65%. To achieve this efficiency, the temperature of the combustion gases on the turbine component surface is expected to reach as high as ~1700ºC (3100ºF). However, SiC/SiC composites suffer from volatilization at high temperature under high velocity steam environment – typical in a turbine hot chamber. This integrated collaborative project, between two research groups at Clemson University and a team of engineers and scientists at GE Gas Power, focused on design, fabrication and evaluation of a new graded environmental barrier coating. Using the excellent compositional tailorability of polymer derived ceramics (PDCs), we developed an integrated EBC/BC that smoothly transitions from bottom SiC/SiC bond interface to hermetic sesquioxide (Y 2 O 3 ) top surface. This smooth compositional transition avoided the sharp CTE mismatch at interfaces to greatly reduce the thermal stress. The developed EBC is compatible with and bonds well with the bond coat that GE uses. The top hermetic oxide surface ensures low oxygen transportation and volatilization rates under the high velocity steam environment. The graded microstructure with increasing sesquioxide concentration also decreases the amount of Si and C elements near the top hermetic sesquioxide layer. Coatings made using a process suitable for manufacturing – atmospheric plasma spraying was demonstrated. The microstructure of coatings made using this process were fully characterized. Finally, the performance of these coatings was investigated under the most demanding conditions for this application. Specifically, high temperature, high velocity steam exposure; thermal shock test; and thermal cycling tests. The graded coatings performed exceptionally well in all these tests. Specific suggestions for future development in this area have also been identified. In addition to the excellent technical progress, this project helped initiate a robust collaboration between the research groups at Clemson and GE Gas Power. It also provided a high-quality learning and mentoring opportunity for the three post-doctoral research associates and two UG students at Clemson University who worked on this project. All proposed tasks, sub-tasks were completed, and all milestones achieved.
03 NATURAL GAS↗
Enhanced lightning strike protection using vertically oriented carbon fiber melded with conventional carbon fiber-reinforced composite and its validation through damage analysis
Lightning strike protection (LSP) is one of the prime factors in aerospace and wind industries concerning safety, enhanced service life, and reduced downtime. To ensure better LSP, high electrical conductivity is required to dissipate the current, which is always a challenge for polymer composites due to the inherent insulating nature of the polymer matrix. Conventional carbon fiber-reinforced composites (CFRP) offer electrical conductivity in the planar direction while the vertical i.e. through-thickness conductivity still remains a challenge. Having been motivated by this fact, we have fabricated CFRP interleaved with vertically oriented CF (Z-fiber) for the lightning strike test (100 kA). A paint was applied to mimic the actual service condition of the composite laminates. We have prepared two Z-fiber composites: (a) Z-1 containing one Z-fiber layer on the top along with conventional CF layers and (b) Z-5 containing five interleaved Z-fiber layers and compared the properties with conventional CFRP (Z-0). Interestingly, even a single Z-fiber layer (Z-1) showed lower damage (visual damage diameter 22 mm) than Z-0 (visual damage diameter 26 mm). Z-5 displayed the lowest damage (visual damage diameter 16.7 mm), which was further confirmed by cross-sectional optical microscopy. Improved LSP was attributed to the higher through-thickness electrical conductivity in the case of Z-5 (9 times with respect to Z-0) reflecting a lower electrical anisotropy for Z-fiber composites. The residual mechanical property after the lightning test was analyzed through the flexural test, and the retention of flexural strength and modulus was 66% and 86%, respectively for Z-5 showing a significant improvement in comparison to Z-0 (>40% for both).
Saha, Subhabrata↗