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In this work, we present a multimodal approach to three-dimensionally quantify and visualize fiber orientation and resin-rich areas in carbon-fiber-reinforced polymers manufactured by vacuum infusion. Three complementary image modalities were acquired by Talbot–Lau grating interferometer (TLGI) X-ray microcomputed tomography (XCT). Compared to absorption contrast (AC), TLGI-XCT provides enhanced contrast between polymer matrix and carbon fibers at lower spatial resolutions in the form of differential phase contrast (DPC) and dark-field contrast (DFC). Consequently, relatively thin layers of resin, effectively indiscernible from image noise in AC data, are distinguishable. In addition to the assessment of fiber orientation, the combination of DPC and DFC facilitates the quantification of resin-rich areas, e.g., in gaps between fiber layers or at binder yarn collimation sites. We found that resin-rich areas between fiber layers are predominantly developed in regions characterized by a pronounced curvature. In contrast, in-layer resin-rich areas are mainly caused by the collimation of fibers by binder yarn. Furthermore, void volume around two adjacent 90°-oriented fiber layers is increased by roughly 20% compared to a random distribution over the whole specimen.

Additive manufacturing (AM) unlocks novel industrial possibilities in relation to design optimisation for lightweight structures, e.g. in aerospace applications. However, the inherent geometric com...

In this study, we investigated specimens of artificial bone foams, developed by the research group for surgical simulators at the UAS Linz, which are used to mimic the haptic feedback of physiologic and pathologic bone for more realistic surgery training. Specimens with two kinds of mineral filler material as well as different amounts of foaming agent were tested in an environmental in-situ loading stage developed by the ITAM CAS and scanned via X-ray micro-computed tomography. In this in-situ stage, specimens can be immersed in liquid and tested under temperature-controlled conditions. Consequently, a total amount of 12 specimens was subjected to compression loading; half of them immersed in water at 36.5◦C and half in dry condition. Results showed that there is no significant influence of liquid immersion to the compression outcome. However, foams with less amount of foaming agent appeared to have smaller pores resulting in higher compression strength.

Light-weight cellular solids, such as aluminium foams, are promising materials for use in ballistic impact mitigation applications for their high specific deformation energy absorption capabilities. In this study, three different types of aluminium alloy based in-house fabricated cellular materials were subjected to dynamic penetration testing using an in-house experimental setup to evaluate their deformation and microstructural response. A two-sided direct impact Hopkinson bar apparatus instrumented with two high-speed cameras observing the impact area and the penetrated surface of the specimens was used. An advanced wave separation technique was employed to process the strain-gauge signals recorded during the penetration. The images captured by one of the cameras were processed using an in-house Digital Image Correlation method with sub-pixel precision, that enabled the validation of the wave separation results of the strain-gauge signals. The second camera was used to observe the penetration into the tested specimens for the correct interpretation of the measured signals with respect to the derived mechanical and the microstructural properties at the different impact velocities. A differential X-ray computed tomography of the selected specimens was performed, which allowed for an advanced pre- and post-impact volumetric analysis. The results of the performed experiments and elaborate analysis of the measured experimental data are shown in this study.

Commercial carbon fibre (CF) fabrics are frequently equipped with an epoxy-based (EP) sizing, which is required for fibre protection during weaving but unsuitable for subsequent thermoplastic processing due to incompatibility. The present study investigates a heat treatment method of CF fabrics in order to remove the incompatible sizing and promote interfacial adhesion with thermoplastic matrices through the oxidised carbon surface. The removal of the EP-sizing from CF fabrics (desizing) was conducted by infrared-irradiation (IR) in air atmosphere at 400 °C. IR-desized CF fabrics were confirmed to be free from sizing residues by SEM imaging and thermogravimetric analysis. Subsequently, CF-PA6, CF-PPS and CF-PEEK thermoplastic composite laminates (TPCL) were manufactured by means of film stacking and hot compression moulding with fibre volume fractions ranging from 45-47%. For comparative purposes, the in-house moulded TPCL were benchmarked against state-of-the-art industrial TPCL in 3-point flexural, short-beam flexural and Charpy impact tests. Overall, very similar performance was attained between IR-desized TPCL and their industrial counterparts. Excellent wet-out and interfacial adhesion of IR-desized CF was observed from SEM imaging of fractured laminates. Conversely, TPCL prepared from EP-sized CF fabrics were found to be neither sufficiently consolidated nor thoroughly wetted out by the thermoplastic matrix, confirming poor interfacial compatibility. The correspondingly poor mechanical performance of EP-sized TPCL emphasised the importance of EP-sizing removal.

Background Because of the accumulated numbers and the increasing rate of knee replacement surgeries larger numbers of revision cases are likely. Although the success rate of knee arthroplasties is high, complications like the loosening of the implant necessitate subsequent treatments. Therefore, new concepts such as metal-free ceramic implants are necessary, for example, using zirconium dioxide (ZrO2). Several studies showed that the strength of ceramic ZrO2 implants is equivalent to cobalt-chromium components. Methods Non-destructive testing remains challenging due to the high density (6 g/cm³) of ZrO2. In this feasibility study, we investigated 8 tibial and 8 femoral implants respectively using an industrial X-ray micro-computed tomography (XCT) system at a voxel size of 100 μm. We established a non-destructive testing protocol for ceramic knee implants optimizing scanning parameters and sample orientation using CT simulations. Finally, we used an iterative artifact reduction procedure for beam hardening correction. Results The results show that corrected image data enable the non-destructive inspection of high-density components. In this sample, none of the investigated components show any internal defects like pores or cracks. In general, XCT is a major imaging method that is able to provide a 3-dimensional representation of higher dense objects that allows the inspection of metal or ceramic knee implants. Even though we established an optimized scanning routine for tibial and femoral ceramic components, it is not possible to completely eliminate scanning artifacts of XCT. Conclusion Altogether, after visual inspection, none of the beam-hardening corrected XCT data sets for femoral and tibial implants showed any defects, that is, no inclusions, cracks, or pores were detected. XCT test is therefore an essential addition to the fatigue testing since it is the only non-destroying testing method.