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Results for “polymer-matrix composites”

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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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Study on Fracture of Fiber-Reinforced Polymeric Composites Using Spiral Notch Torsion Test

Fiber-reinforced polymer-matrix composites have been widely applied in various areas due to their excellent mechanical properties. In this study, carbon fiber-reinforced polymer-matrix composites and glass fiber-reinforced polymer-matrix composites failure tests under quasi static torsion have been demonstrated by using spiral notch torsion test methodology. Three types of cylindrical specimens with different fiber orientations were prepared and tested. For both composites, after increase stage, A type exhibited limited stress variations before the sudden failure, whereas B type showed gradual failure with torque drops. Displacement contours, stress contours and energy release rates were acquired using the anisotropic elastic finite element models. Microscopic characterization exhibited that the failure of A type occurred along interfaces between fibers and matrices, whereas circular cracks in B type propagated alternatively between polymeric matrices and interfaces. Type C failure is similar to type A whereas with a curvature observed on the fracture surface.

Du, Fen↗
DOE OSTI2022

Anisotropic Thermally Conductive Composites Enabled by Acoustophoresis and Stereolithography

Opportunities to improve thermal management in electronic devices are currently hindered by processing constraints that limit thermal conductivity in polymer-matrix composites. Active patterning of filler particles is a promising route to improve conductivity while retaining processability by improving particle contact density and directing heat along optimized pathways. Here, we employ acoustic patterning to align and compact filler particles into stripes during stereolithographic 3D printing. This approach produces polymer-based composite materials with highly efficient embedded heat transport pathways which reach 95 vol% particle utilization (relative to the parallel conduction upper limit). These composites exhibit anisotropic thermal conductivity up to 300% higher than unpatterned composites, with in-plane anisotropy ratios of up to 350%. Combining this high conductivity with 3D printing enables materials with engineered heat networks that optimize transport from hot spots to heatsinks while maintaining low viscosity for fast particle patterning and for infiltration around electronic components. Finally, numerical simulations of acoustic assembly of particles with varied geometry, when compared to experimentally characterized particle packing, illuminate pathways for further improving conductivity by optimizing particle geometry for alignment and stacking of particles with maximum contact surface area.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Pulsed ytterbium-doped fibre laser with a combined modulator based on single-wall carbon nanotubes

This paper describes an all-normal-dispersion pulsed ytterbium-doped fibre ring laser mode-locked by a nonlinear combined modulator based on single-wall carbon nanotubes. We have demonstrated 1.7-ps pulse generation at 1.04 μm with a repetition rate of 35.6 MHz. At the laser output, the pulses were compressed to 180 fs. We have examined an intracavity nonlinear modulator which utilises nonlinear polarisation ellipse rotation in conjunction with a saturable absorber in the form of a polymer-matrix composite film containing single-wall carbon nanotubes. (lasers)

36 MATERIALS SCIENCE↗
DOE OSTI2022

Compressive strength of the plastic-bonded explosive surrogate idoxuridine under quasistatic and dynamic compression

Inert simulant materials, or “mocks”, are often used as surrogates for plastic-bonded explosives (PBX) in non-detonative tests in order to mitigate hazards. Mocks should reproduce as many non-detonative properties of the explosive as possible, including structural behavior in a variety of thermal and mechanical environments. Recently, the molecular crystal idoxuridine (IDOX) has been identified as an ideal mock for the main component in the explosive polymer-matrix composite PBX 9501, and has performed favorably under quasistatic loading conditions. Here, in order to assess robustness over a range of mechanical environments, plastic-bonded IDOX was compression tested from 0.001/s to 2000/s strain rates and compared to PBX 9501 historical data. Plastic-bonded IDOX showed good agreement to PBX 9501 across these strain rates, justifying continued development and production as a mock.

Burch, Alexandra C.↗
DOE OSTI2020

Real-time cure monitoring of fiber-reinforced polymer composites using infrared thermography and recursive Bayesian filtering

Despite the desirable characteristics of fiber-reinforced polymer (FRP) composites, their utilization in high volume production industries is limited by a lack of efficient manufacturing techniques. Monitoring the curing process of these composites can help with improving the quality and efficiency of the manufacturing process. This article discusses a method that uses Kalman-filter-based fusion of the information obtained from infrared thermography (surface temperature measurements) and a heat conduction model to estimate degrees of cure and internal temperatures of curing FRP composite parts in real time. The effectiveness of the methodology is demonstrated by successfully monitoring the curing of an FRP composite part in a laboratory experiment. Finally, the proposed methodology is a crucial step towards identifying anomalies in the curing process that negatively impact the quality of FRP composite parts.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Self-healing carbon fiber/epoxy laminates with particulate interlayers of a low-melting-point alloy

In order to prolong the service life of fiber-reinforced polymer composites, the implementation of self-healing ability with the micro-encapsulated healing agent has been extensively studied. However, such microcapsule-based self-healing composites typically suffer from degraded mechanical properties due to the liquid-phase inclusions, thereby limiting their proliferation. Here, in this study, a low-melting-point alloy is utilized as the particulate inclusions of carbon fiber/epoxy laminated composites. Field's Metal particles (melting point: 62 °C) are distributed between woven carbon fiber preforms followed by the resin impregnation to realize laminated composites with a Field's Metal-enhanced interlayer(s). The resulting laminated composites demonstrate the autonomic repair of interlaminar failure with a 40 % of healing efficiency. Most of all, the mechanical properties of these self-healing laminated composites are comparable to the conventional laminated composites attributed to the rigid inclusions that can be compressed to increase the fiber volume. Since the Field's Metal particle inclusions can bestow polymer composites with self-healing ability and the potential increase in mechanical properties, Field's Metal-enhanced fiber-reinforced polymer composites are expected to unlock the practical utility of self-healing composites.

A. polymer-matrix composites (PMCs)↗
DOE OSTI2016

Elastic magnetic composites for energy storage flywheels

The bearings used in energy storage flywheels dissipate a significant amount of energy and can fail catastrophically. Magnetic bearings would both reduce energy dissipation and increase flywheel reliability. The component of magnetic bearing that creates lift is a magnetically soft material embedded into a rebate cut into top of the inner annulus of the flywheel. Because the flywheels stretch about 1% as they spin up, this magnetic material must also stretch and be more compliant than the flywheel itself, so it does not part from the flywheel during spin up. At the same time, the material needs to be sufficiently stiff that it does not significantly deform in the rebate and must have a sufficiently large magnetic permeability and saturation magnetization to provide the required lift. It must also have high electrical resistivity to prevent heating due to eddy currents. In this paper we investigate whether adequately magnetic, mechanically stiff composites that have the tensile elasticity, high electrical resistivity, permeability and saturation magnetism required for flywheel lift magnet applications can be fabricated. Lastly, we find the best composites are those comprised of bidisperse Fe particles in the resin G/Flex 650. The primary limiting factor of such materials is the fatigue resistance to tensile strain.

25 ENERGY STORAGE↗
DOE OSTI2023

Degradation in interfacial shear strength of carbon fiber/ vinyl ester composites due to long-term exposure to seawater using push-out tests

Here, in this study, single fiber (~7-μm diameter) push-out tests are conducted to evaluate hygrothermal effects on the interfacial shear strength (IFSS) of carbon fiber/vinyl ester (CF/VE) composites. Hygrothermal conditioning is achieved by saturating samples in simulated seawater at 40 °C for two years. An investigation has been conducted on the preparation, validity, and interpretation of the push-out test results. First, the authors present a polishing methodology that results in thin films of CF/VE composites in the thickness range of 15–120 μm and produces an average 41.2% drop in IFSS due to long-term hygrothermal exposure. Using scanning electron microscopy (SEM), we show that during the push-out tests, the failure initiates locally at the zone of minimum bond strength at the bottom (away from the indenter), then propagates along the length of the interface. The influence of radial tensile stresses originating due to bending is found to be negligible. Using the SEM imaging of the pushed-out fibers, we validate the failure of the interface to be the primary source of failure. The associated results are found to depend on the thickness of the interface. We then reevaluate the results using the Weibull distribution, knowing that the failure mechanism is analogous to the weakest link theory. The results show a 25.5% drop in the IFSS of the CFVE composite, measured at an infinitesimal scale due to long-term to hygrothermal conditioning at 40 °C. A significant drop in IFSS was observed after reheating above glass transition temperature (T g ) and cooling.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Analysis of tow architecture variability in biaxially braided composite tubes

Spatial deviations in composite braid unit cell dimensions limit mechanical performance and are challenging to model. Full-field measurements of the irregular tow placement in biaxially braided composite tubes were obtained by digital image correlation. Analysis of the reconstructed tow paths showed long-range defects along the hoop direction with short-range defects dominating the biased tow direction. A route toward numerical simulation of the composite response is established by developing a 3D model of the composite using the measured tow trajectories. Finally, a comparison to previously-published triaxial braid results indicates axial tows work to constrain unit cells dimensions along the hoop direction.

3-Dimensional reinforcement↗
DOE OSTI2026

Effects of cleavable comonomer structure and crosslinker chemistry on the performance and deconstructability of frontally cured pDCPD composites

Reclaiming undamaged carbon fiber from thermoset composites requires chemical recycling methods that leverage complete deconstruction of the polymer matrix. Cleavable comonomers enable chemical recycling of poly(dicyclopentadiene) (pDCPD) composites, but current systems suffer from reduced glass transition temperature (T g ), limiting application. Here, we investigate the effect of cleavable comonomer loading and cleavable crosslinker chemistry on network formation, thermomechanical properties, and fiber recovery in frontally cured pDCPD composites. All formulations fully deconstructed in acid and recovered fibers ranged from pristine to variably contaminated depending on crosslinker chemistry. Reducing backbone-cleaving comonomer content and introducing cleavable crosslinkers raised composite T g to 126–138 °C compared to 105 °C previously reported in deconstructable pDCPD composites. Although the cleavable crosslinkers increased T g in unreinforced polymers to 150–160 °C, the fiber-reinforced composite T g remained lower due to under-curing and interactions between the crosslinkers and the fiber surface. Increasing polymerization initiator loading improved comonomer conversion and yielded a deconstructable composite with T g = 151 °C, approaching the performance of non-deconstructable pDCPD composites (T g = 161 °C). This work clarifies how cleavable comonomer and crosslinker chemistry governs curing, thermomechanical performance, and reclaimed reinforcement quality, and the results highlight the need for more robust cleavable comonomers to realize multigenerational composite materials without sacrificing thermomechanical performance.

Carbon fibers↗
DOE OSTI2022

Multiscale and multiphysics FEA simulation and materials optimization for laser ultrasound transducers

In this study, the relationship between the nanocomposite design and the laser ultrasound transducer (LUT) characteristics was investigated through simulations in multiple scale levels for material behavior, device response, and acoustic wave propagation in media. First, the effects of the nanoparticle size and concentration on the effective properties of composites were quantitatively investigated with the finite element analysis (FEA) method. Second, the effective properties of the nanocomposite were assigned to the layer, which is modeled as a homogeneous material, in the FEA for the LUT simulating the energy conversion from the incident laser to the acoustic wave. Finally, the ultrasound propagation in the water was calculated by a theoretical wave propagation model. The FEA-based prediction was compared with the experimental data in the literature and a theoretical analysis for LUT based on Thermal-Acoustic coupling. As a result, the ultrasound waves on the transducer surface and at a distance in the water could be predicted. Based on the hierarchically integrated prediction procedure, the optimal conditions of the photoacoustic nanocomposites were investigated through the parametric study with the particle size and concentration as variables. The results guide the material designs optimized for different device characteristics, such as high pressure and broad bandwidth.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Recent advancements of plant-based natural fiber–reinforced composites and their applications

Demands for reducing energy consumption and environmental impacts are the major driving factors for the development of natural fiber–reinforced composites (NFRCs) in many sectors. Compared with synthesized fiber, natural fiber provides several advantages in terms of biodegradability, light weight, low price, life-cycle superiority, and satisfactory mechanical properties. However, the inherent features of plant-based natural fibers have presented challenges to the development and application of NFRCs, such as variable fiber quality, limited mechanical properties, water absorption, low thermal stability, incompatibility with hydrophobic matrices, and propensity to agglomeration. Substantial research has recently been conducted to address these challenges for improved performance of NFRCs and their applications. This article reviews the recent advancements of plant-based NFRCs, focusing on strategies and breakthroughs in enhancing the NFRCs’ performance, including fiber modification, fiber hybridization, lignocellulosic fillers incorporation, conventional processing techniques, additive manufacturing (3D printing), and new fiber source exploration. In conclusion, the sustainability of plant-based NFRCs using life-cycle assessment and the burgeoning applications of NFRCs with emphasis on the automotive industry are also discussed.

3D reinforcement↗
DOE OSTI2024

Supersonic hot jet ablative testing and analysis of boron nitride nanotube hybrid composites

Boron nitride nanotubes (BNNTs) are high-strength, high-modulus nanotubes with high thermal and oxidative stabilities. Two hybrid composites were prepared with satin weave carbon fiber (CF) and resole-type phenolic resin: one with surface layers of BNNTs and one with alternating interlayers of BNNTs. The samples were subjected to hot jet tests that simulate realistic high-pressure-temperature conditions to understand the behavior of BNNTs under high-pressure erosion. Adding BNNTs to CF/phenolic laminates enhanced the ablation resistance by reinforcing the char material and mitigated localized thermal damage. Hybrid laminates exhibited up to 14% lower weight loss, 55% increase in flexural modulus, higher thermal diffusivity, and improved char yield and microstructure compared to CF/phenolic samples. The surface layer hybrid had many surviving nanotubes reinforcing the char and crystalline oxide structures that could mitigate further oxygen diffusion. Further, various characterization methods were used to deduce possible mechanisms and their products, indicating that BNNTs could serve as growth templates for direct crystalline boron oxide formation. Overall, hybrid BNNT/CF/phenolic laminates displayed better ablation resistance and favorable microstructure evolution under high-pressure conditions.

42 ENGINEERING↗
DOE OSTI2015

Platelet composite coatings for tin whisker mitigation

In this study, reliable methods for tin whisker mitigation are needed for applications that utilize tin-plated commercial components. Tin can grow whiskers that can lead to electrical shorting, possibly causing critical systems to fail catastrophically. The mechanisms of tin whisker growth are unclear and this makes prediction of the lifetimes of critical components uncertain. The development of robust methods for tin whisker mitigation is currently the best approach to eliminating the risk of shorting. Current mitigation methods are based on unfilled polymer coatings that are not impenetrable to tin whiskers. In this paper we report tin whisker mitigation results for several filled polymer coatings. The whisker-penetration resistance of the coatings was evaluated at elevated temperature and high humidity and under temperature cycling conditions. The composite coatings comprised Ni and MgF 2 -coated Al/Ni/Al platelets in epoxy resin or silicone rubber. In addition to improved whisker mitigation, these platelet composites have enhanced thermal conductivity and dielectric constant compared with unfilled polymers.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Particle clustering effects on damage mechanisms in elastomeric syntactic foams

To elucidate the damage mechanisms in syntactic foams with hollow glass microballoon (GMB) reinforcement and elastomer matrices, in situ X-ray computed tomography mechanical testing was performed on syntactic foams with increasing GMB volume fraction. Image processing and digital volume correlation techniques identified very different damage mechanisms compared to syntactic foams with brittle matrices. Specifically, the prevailing mechanism transitioned from dispersed GMB collapse at low volume fraction to clustered GMB collapse at high volume fraction. Moreover, damage initiated and propagated earlier in closely-packed GMBs for all specimens. Both of these trends were attributed to increased interaction between closely-packed GMBs. This was validated by statistical analysis of GMB damage, which identified a consistent, inverse relationship among the probability of survival and the local coordination number (N neighbor ) across all specimens.

42 ENGINEERING↗
DOE OSTI2022

Significant slowdown of plasma-optimized surface energy deactivation by vacuum sealing for efficient adhesive bonding

This work proposes an approach to minimize surface energy deactivation of plasma-treated metal and carbon fiber-reinforced polymer (CFRP) surfaces by vacuum sealing. Plasma treatments enhance adhesive wettability on post-treated surfaces for adhesive joints, but the treated surfaces deactivate quickly in air. The surface energy of aluminum alloy AA6061 and carbon fiber-reinforced polymer-polyamide (CFRP-PA66) optimally treated by a blown air plasma instrument returns to the original surface energy within one hour. Vacuum sealing of AA6061 and CFRP-PA66 reduced the surface energy deactivation over 7 days by at least 230 times and 970 times compared to in air. Double Cantilever Beam (DCB) tests performed on adhesively-bonded AA6061/CFRP-PA66 joints showed that the total energy release and energy dissipation before failure of plasma-treated and vacuum-sealed materials was up to 60% more than plasma-treated materials without vacuum sealing and up to 125% more than non-plasma-treated materials.

42 ENGINEERING↗
DOE OSTI2024

Understanding surfaces and interfaces in nanocomposites of silicone and barium titanate through experiments and modeling

Barium titanate (BTO) is a ferroelectric perovskite used in electronics and energy storage systems because of its high dielectric constant. Decreasing the BTO particle size was shown to increase the dielectric constant of the perovskite, which is an intriguing but contested result. We investigated this result by fabricating silicone-matrix nanocomposite specimens containing BTO particles of decreasing diameter. Furthermore, density functional theory modeling was used to understand the interactions at the BTO particle surface. Combining results from experiments and modeling indicated that polymer type, particle surface interactions, and particle surface structure can influence the dielectric properties of polymer-matrix nanocomposites containing BTO.

composite↗
DOE OSTI2016

Cavitation-Induced Stiffness Reductions in Quantum Dot–Polymer Nanocomposites

The elastic stiffness of two polymer nanocomposite systems is investigated. The nanoscale fillers comprise cadmium selenide (CdSe, ~4 nm) and cadmium selenide/cadmium sulfide (CdSe/CdS, ~13 nm) quantum dots (QDs). The QDs are embedded within an electrospun structural block copolymer, poly(styrene-ethylene-butylene-styrene) (SEBS). Tensile testing shows a monotonic decrease in the tensile Young's modulus with increasing partially phase-separated QD concentration; this is to be compared to corresponding nanocomposites reinforced with nanorod (NR) and tetrapod (TP)-SEBS nanocomposites which show a monotonic increase with particle loading. While most studies to date emphasize the increase in Young's modulus in polymer nanocomposites at higher reinforcement loadings, few focus on the tunability of the modulus from reductions in stiffness. The present work reveals up to an ~80% reduction in tensile Young's modulus with the addition of 5 vol % of QDs to electrospun SEBS. In this study, we sought mechanistic insight into this reduction in composite stiffness using a 2D lattice spring model. Simulation results reveal that the stiffness decrease with the addition of QD reinforcements is likely due to cavitation in the polymer in the vicinity of the QD aggregates arising from polymer debonding under tension. We anticipate that this study, performed with a commonly used structural rubber, may find use in designing polymer-matrix nanocomposite fibers with specific Young's moduli for applications requiring a tunable lower stiffness material.

36 MATERIALS SCIENCE↗