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A promising strategy to increase the tensile failure strain of carbon fibre-reinforced composites is to hybridise carbon fibres with other, higher-elongation fibres. The resulting increase in failure strain is known as the hybrid effect. In the present article, a global load-sharing model for hybrid composites is developed and used to carry out a parametric study for carbon/glass hybrids. Hybrid effects of up to 15% increase in failure strain are predicted, corresponding reasonably well to literature data. Scatter in the carbon fibre strength is shown to be crucial for the hybrid effect, while the scatter in glass fibre strength is much less important. In contrast to reports in earlier literature, the ratio of failure strains of the two fibres has only a small influence on the hybrid effect. The results provide guidelines for designing optimal hybrid composites.

This paper presents the development of novel Carbon-Fibre Reinforced Polymer (CFRP) laminates, tailored for the application of Digital Volume Correlation (DVC) and Computed Tomography (CT) to experimental mechanics analyses of these materials. Analogous to surface-based Digital Image Correlation (DIC), DVC is a relatively novel volumetric method that utilizes CT data to quantify internal three-dimensional (3D) displacements and implicit strain fields. The highly anisotropic and somewhat regular/self-similar microstructures found in well-aligned unidirectional (UD) materials at high fibre volume fractions are intrinsically challenging for DVC, especially along the fibre direction at microstructural length-scales on the order of a few fibre diameters. To permit the application of DVC to displacement and/or strain measurements parallel to the fibre orientation, the matrix was doped with a sparse population of sub-micrometre particles to act as displacement trackers (i.e. fiducial markers). Barium titanate particles (400 nm, ∼1.44 vol. %) were found to offer the most favourable compromise between contrast in CT images and the ability to obtain a homogeneous distribution in 3D space with sufficient particle compactness for local DVC analyses. This property combination was selected following an extensive Micro-focus Computed Tomography (µCT)-based qualitative assessment on a wide test matrix, that included 38 materials manufactured with a range of possible particle compositions, mean sizes and concentrations. By comparing the tensile behaviour of the particle-adapted material alongside its particle-free counterpart, we demonstrate through the application of in situ Synchrotron Radiation Computed Tomography (SRCT) that the macro- and micromechanical responses of the newly developed CFRP are consistent with standard production materials indicating its suitability as a model system for mechanistic investigations. [ABSTRACT FROM AUTHOR]

In fiber-reinforced polymer composites, the fiber-matrix interface controls stress transfer mechanisms, thereby affecting mechanical performance. Interfacial properties are often extracted via single-fiber composite tests. In these tests, the load is transferred from the polymer to the fiber through interfacial shear stresses, necessitating the evaluation of interfacial shear properties. To adopt these properties in the design of industrially relevant composites, one must assume that the damage mechanisms in single-fiber composites are representative of those in multi-fiber composites, consisting of highly aligned, unidirectional plies with high fiber volume fractions. That assumption, however, has never been validated. In this paper, the real-time damage development is monitored in single-fiber and multi-fiber composites using in situ X-ray holo-tomography at 150-nm pixel size. The technique enables the first-ever 3D detection of longitudinal interfacial debonding in carbon and glass single-fiber composites. This mechanism is not detected in multi-fiber composite specimens, suggesting that single-fiber composites are intrinsically unrepresentative of realistic composite behavior., (© 2024 Wiley‐VCH GmbH.)

Carbon fiber-reinforced polymer (CFRP) composite materials are widely used in engineering applications, but their production generates a significant amount of waste. This paper aims to explore the potential of incorporating mechanically recycled aerospace prepreg waste in thermoplastic composite materials to reduce the environmental impact of composite material production and promote the use of recycled materials. The composite material developed in this study incorporates a bio-based thermoplastic polymer, polyamide 11 (PA11), as the matrix material and recycled aerospace prepreg waste quasi-one-dimensionally arranged as reinforcement. Mechanical, thermal, and thermomechanical characterizations were performed through tensile, flexural, and impact tests, as well as differential scanning calorimetry (DSC) and dynamic mechanical analysis (DMA). Compared to previous studies that used a different recycled CFRP in the shape of rods, the results show that the recycled prepregs are a suitable reinforcement, enhancing the reinforcement-matrix adhesion and leading to higher mechanical properties. The tensile results were evaluated by SEM, and the impact tests were evaluated by CT scans. The results demonstrate the potential of incorporating recycled aerospace prepreg waste in thermoplastic composite materials to produce high-performance and sustainable components in the aerospace and automotive industries.

Fibre breaks govern the strength of unidirectional composite materials under tension. The progressive development of fibre breaks is studied using in situ X-ray computed tomography, especially with synchrotron radiation. However, even with synchrotron radiation, the resolution of the time-resolved in situ images is not sufficient for a fully automated analysis of continuous mechanical deformations. We therefore investigate the possibility of increasing the quality of low-resolution in situ scans by means of super-resolution (SR) using 3D deep learning techniques, thus facilitating the subsequent fibre break identification. We trained generative neural networks (GAN) on datasets of high-(0.3 μm) and low-resolution (1.6 μm) statically acquired images. These networks were then applied to a low-resolution (1.1 μm) noisy image of a continuously loaded specimen. The statistical parameters of the fibre breaks used for the comparison are the number of individual breaks and the number of 2-plets and 3-plets per specimen volume. The fully automated process achieves an average accuracy of 82% of manually identified fibre breaks, while the semi-automated one reaches 92%. The developed approach allows the use of faster, low-resolution in situ tomography without losing the quality of the identified physical parameters.

Understanding the fatigue behaviour of hybrid fibre-reinforced plastics is desirable for exploiting their features in safe, durable and reliable industrial components. The fatigue performance of hybrid composites has not been extensively investigated yet. The paper presents an overview of the available knowledge on the fatigue of hybrid fibre-reinforced plastics, and, more specifically, reports the fatigue behaviour of a quasi-isotropic pseudo-ductile all-carbon fibre interlayer hybrid composite by experimental measurements and observations, with emphasis on the damage development. The fatigue conditions are tension-tension stress- and strain-controlled cyclic loading. The results include fatigue life for different maximum stress and strain levels, stiffness evolution and damage observations by X-ray micro-computed tomography. The studied hybrid all-carbon fibre quasi-isotropic composite exhibits pseudo-ductility in quasi-static testing. For stress-controlled fatigue, the fatigue load over the limit of elastic response is not sustained. Contrary to that, the composite retains its load-carrying ability in the pseudo-ductile regime for a strain-controlled regime, albeit with lowered stiffness. This article is part of the theme issue 'Ageing and durability of composite materials'.

The increasing use of carbon fiber and epoxy resin composite materials yields an increase in the amount of waste. Therefore, we present a solution consisting of composites manufactured by hot pressing, employing polyamides (either PA11 or PA12) and a mechanically recycled carbon fiber-reinforced polymer (CFRP) as reinforcement. The main objectives are to study the manufacturing of those composites, to evaluate the fiber distribution, and to perform a mechanical, dynamical, and thermomechanical characterizations. The X-ray micro-computed tomography (μCT) shows that the fibers are well-distributed, maintaining a homogeneous fiber volume fraction across the material. The variability in the results is typical of discontinuous fiber composites in which the fibers, although oriented, are not as homogeneously distributed as in a continuous fiber composite. The mechanical and dynamic properties barely differ between the two sets of composites. A dynamic-mechanical analysis revealed that the glass transition temperature (T g ) increases slightly for both composites, compared to the polymers. These results illustrate the viability of the recycling and reuse route for preventing the deterioration of carbon fibers and promoting the subsequent reduction in the environmental impact by employing a thermoplastic matrix., Competing Interests: The authors declare no conflict of interest. The funders had no role in the design of the study; in the collection, analyses, or interpretation of data; in the writing of the manuscript; or in the decision to publish the results.