Moulding prepreg platelets into high fibre loading fraction carbon fibre-reinforced syntactic epoxy foams

IF 8.1 2区材料科学 Q1 ENGINEERING, MANUFACTURING

Composites Part A: Applied Science and Manufacturing Pub Date : 2025-03-22 DOI:10.1016/j.compositesa.2025.108865

Yifang Zhang , Jier Wang , Tuomas Turpeinen , Kristian Salminen , Joanne Li , Dharu Feby Smaradhana , Ajit Panesar , Koon-Yang Lee

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Abstract

This study presents a novel method for manufacturing high fibre content carbon fibre-reinforced syntactic epoxy foams by moulding prepreg platelets with hollow glass microspheres. The prepreg platelets were either (i) dry-mixed at room temperature or (ii) mixed at cryogenic temperature in liquid nitrogen with hollow glass microspheres prior to compression moulding. This approach achieves a carbon fibre volume fraction of up to 49 %, addressing the limitations of low fibre content in conventional syntactic foams. The resulting materials exhibit enhanced mechanical properties, including a compressive modulus of ∼6 GPa and ∼3.5 GPa in the in-plane and through-thickness directions, respectively. The anisotropy in mechanical properties is attributed to the anisotropic packing of the prepreg platelets. Packing simulations using PyBullet confirmed that microspheres did not disrupt platelet arrangement, maintaining a packing efficiency of ∼63 % while filling inter-platelet gaps. Although cryogenic processing improved the mixing process, its impact on mechanical performance was minimal. This study demonstrates a simple manufacturing approach to produce high performance carbon fibre reinforced porous polymer composites suitable for lightweighting applications.

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来源期刊

Composites Part A: Applied Science and Manufacturing 工程技术-材料科学：复合

CiteScore

15.20

自引率

5.70%

发文量

492

审稿时长

30 days

期刊介绍： Composites Part A: Applied Science and Manufacturing is a comprehensive journal that publishes original research papers, review articles, case studies, short communications, and letters covering various aspects of composite materials science and technology. This includes fibrous and particulate reinforcements in polymeric, metallic, and ceramic matrices, as well as 'natural' composites like wood and biological materials. The journal addresses topics such as properties, design, and manufacture of reinforcing fibers and particles, novel architectures and concepts, multifunctional composites, advancements in fabrication and processing, manufacturing science, process modeling, experimental mechanics, microstructural characterization, interfaces, prediction and measurement of mechanical, physical, and chemical behavior, and performance in service. Additionally, articles on economic and commercial aspects, design, and case studies are welcomed. All submissions undergo rigorous peer review to ensure they contribute significantly and innovatively, maintaining high standards for content and presentation. The editorial team aims to expedite the review process for prompt publication.