{"title":"Recent progress in non-planar 3D printing of continuous fiber-reinforced composites","authors":"Ping Cheng, Zhi Han, Yuan Chen, Lin Ye","doi":"10.1016/j.compositesa.2025.108900","DOIUrl":"10.1016/j.compositesa.2025.108900","url":null,"abstract":"<div><div>In recent years, additive manufacturing techniques have been increasingly applied in the production of continuous fiber-reinforced composites (CFRCs). However, most advancements have focused on the fabrication of planar CFRC structures, whereas many engineering applications involve non-planar structures. Progress in 3D printing of non-planar CFRCs remains limited, representing an emerging cutting-edge area with significant potential for engineering applications. This review focuses on the state-of-the-art in non-planar 3D printing techniques for CFRC structures and elaborates their future perspectives and potential challenges. A comprehensive discussion is presented on the distinctions between non-planar and conventional planar 3D printing methods, and the materials and processes currently employed in these studies are critically examined. Three common methods of curved layer slice-path generation for CFRC structure are introduced. In addition, the article specifically addresses various non-planar printing approaches, including support-based techniques, such as three-axis and multi-axis printing, as well as support-free methods relying on rapid cooling and photopolymerization processes. Finally, based on the challenges of non-planar printing techniques in path planning, manufacturing processes, and performance optimization, potential research directions for the future are outlined.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"194 ","pages":"Article 108900"},"PeriodicalIF":8.1,"publicationDate":"2025-03-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143738769","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Yong-Zhang Huo , Jin-Shui Yang , Zhao Suo , Tian Zhao , Wei-Jing Wang , Yao-Hui Tong , Xiang-Wei Wang
{"title":"Low velocity impact response of carbon fiber reinforced thermoplastic composite honeycomb sandwich structure considering mesoscopic damage behavior","authors":"Yong-Zhang Huo , Jin-Shui Yang , Zhao Suo , Tian Zhao , Wei-Jing Wang , Yao-Hui Tong , Xiang-Wei Wang","doi":"10.1016/j.compositesa.2025.108898","DOIUrl":"10.1016/j.compositesa.2025.108898","url":null,"abstract":"<div><div>With the development of carbon fiber reinforced thermoplastic polymer (CFRTP), laminates and core structures made of them are more and more widely used in various field. This paper focuses on analyzing the dynamic response of laminates and sandwich structures made of T700 carbon fiber reinforced Poly Ether-Ether-Ketone (PEEK) thermoplastic composites under a low-velocity impact condition. The honeycomb sandwich structures and laminates were fabricated separately and were subjected to impact loading with different energies. Finite element models were established to explore the failure mechanisms and energy absorption characteristic of the as-manufactured structures. A high-fidelity mesoscopic modelling method was adopted to gain an in-depth insight of the damage behavior of thermoplastic composites. The effects of structural parameters such as panel thickness, core height and core wall thickness on the impact response were systematically studied. Meanwhile, in comparison with thermoset composites, thermoplastic composites showed better impact resistance.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"194 ","pages":"Article 108898"},"PeriodicalIF":8.1,"publicationDate":"2025-03-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143748063","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"A cutting force prediction model for UD-CFRP and MD-CFRP milling based on fracture mechanisms and mechanical properties","authors":"Congle Liu, Junxue Ren, Yali Zhang, Kaining Shi","doi":"10.1016/j.compositesa.2025.108892","DOIUrl":"10.1016/j.compositesa.2025.108892","url":null,"abstract":"<div><div>Due to its exceptional properties, CFRP has become the material of choice for primary load-bearing structural components, such as composite fan blades, in aerospace and other industries. However, its anisotropy, heterogeneity, and unique characteristics make it a challenging material to machine. To address this issue, this paper presents a cutting force prediction model for CFRP milling based on the evolution of fracture mechanisms and material mechanical properties. The model introduces fracture coefficients, slip angle coefficients, and compression coefficients to accurately predict cutting force variations throughout the entire milling process, from tool entry to exit. The model was calibrated using orthogonal cutting experiments and single-angle slot milling experiments on UD-CFRP and further validated through slot milling experiments on UD-CFRP and two types of MD-CFRP, which were all conducted at various angles. Experimental results demonstrate that the proposed model can precisely predict cutting force variations during the entire milling process. Additionally, the model exhibits strong adaptability and scalability, compensating for the variability in CFRP material properties and enabling parameter adjustments for different engineering applications. It can also be applied to different laminate layups, ensuring broader applicability in composite manufacturing. Since the model is built upon fracture mechanisms and material properties, it provides an intuitive representation of the fracture evolution process during machining. The cutting force coefficients effectively characterize the fracture behavior in a straightforward manner. This model demonstrates great potential for machining composite fan blades, particularly in monitoring fracture mechanisms and predicting and controlling damage.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"194 ","pages":"Article 108892"},"PeriodicalIF":8.1,"publicationDate":"2025-03-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143748064","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Yixuan Cao , Siming Shen , Liang Li , Dawei Luo , Xiaotong Wang , Fujie Wang , Zhepeng Di , Enhui Liu , Shuangqiao Yang
{"title":"Upcycling aluminum-plastic packaging waste into high thermal conductivity and fire safety composite","authors":"Yixuan Cao , Siming Shen , Liang Li , Dawei Luo , Xiaotong Wang , Fujie Wang , Zhepeng Di , Enhui Liu , Shuangqiao Yang","doi":"10.1016/j.compositesa.2025.108887","DOIUrl":"10.1016/j.compositesa.2025.108887","url":null,"abstract":"<div><div>Aluminum-plastic multilayer films are widely used in packaging applications. However, such metal/polymer composites are challenging to recycle. And existing separation and recovery methods face problems such as low purity, poor performance and secondary pollution. This study proposes a strategy to directly recycle aluminum-plastic packaging waste (APPW) into materials with high thermal conductivity and excellent fire-safe performance. The melt fluidity and processability of APPW were effectively restored by solid-state shear milling (S<sup>3</sup>M). Expandable graphite (EG) and Expanded graphite (EGx) introduced, acting as a “bridge” between Al flakes present in APPW, forming a continuous Al-EG-EGx thermal conductivity network. Finite element simulations demonstrated that the introduction of Aluminum hydroxide (ATH) reduces the space available for Al and EG, promoting the development of the Al-EG-EGx network. Consequently, the composite achieved a thermal conductivity of 3.43 W/m·K with only 15 wt% graphite content. Moreover, ATH synergized with EG (EGx) to significantly enhance fire-safe performance, reducing the total heat release (THR) and total smoke production (TSP) by 48.2 % and 69.6 %, while achieving an impressive limiting oxygen index (LOI) of 54.7 % and V-0 rating in UL94. Meanwhile, tensile and flexural strengths increased by 50.5 % and 54.6 %. Our work offers a novel solution for recycling metal/polymer composite waste, transforming unrecyclable materials into value-added composites for applications in thermal management of electronic devices.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"194 ","pages":"Article 108887"},"PeriodicalIF":8.1,"publicationDate":"2025-03-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143738763","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Yisen Huang, Haoruo Zhang, Chuxiang Zhou, Jingfeng Tian, Hao Zhang, Liwei Yan, Huawei Zou, Yang Chen, Mei Liang
{"title":"Comparative investigation exploring the role of carbonization features on the ablation behavior of graphite/phenolic and pitch/phenolic composites","authors":"Yisen Huang, Haoruo Zhang, Chuxiang Zhou, Jingfeng Tian, Hao Zhang, Liwei Yan, Huawei Zou, Yang Chen, Mei Liang","doi":"10.1016/j.compositesa.2025.108886","DOIUrl":"10.1016/j.compositesa.2025.108886","url":null,"abstract":"<div><div>This study examines the influence of carbonization features, char structures and microstructures of graphitic carbon (GC) on the ablation behavior of graphite (G) and pre-oxidized mesophase pitch (OMP) modified boron phenolic (BPR) composites. Results showed that the introduced G and OMP can both effectively hinder the growth of defects, while improve the graphitization degree of residue char during ablation. However, some areas of the ablated surface of GBPRs would randomly splashed at an early stage because of the thermal dimensional stability mismatch between G and matrix. But as the OMP underwent a carbonization process, in company with the resin matrix, the ablated surface of OMPBPRs keep complete and smooth. Therefore, we found that the formation of mosaic combination and the compatibility of co-carbonization process are the keys for enhanced ablation performance. These findings would provide some inspirations for the development of more advanced polymer-matrix ablative composites in the future.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"194 ","pages":"Article 108886"},"PeriodicalIF":8.1,"publicationDate":"2025-03-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143734534","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Liang He , Jinghui Zhang , Yu Zheng , Shuning Liu , Xiaobo Liu , Lifen Tong
{"title":"Boosting thermal conductivity and tribological performance of polyarylene ether nitrile synergistically by fabricating SiCws-BNNS multidimensional networks","authors":"Liang He , Jinghui Zhang , Yu Zheng , Shuning Liu , Xiaobo Liu , Lifen Tong","doi":"10.1016/j.compositesa.2025.108888","DOIUrl":"10.1016/j.compositesa.2025.108888","url":null,"abstract":"<div><div>High-end electronic materials need reliable thermal and friction resistance. Here, a self-lubricating and highly thermally conductivity polyarylene ether nitrile (PEN) composite was prepared by surface optimization strategy combined multidimensional network. One-dimensional SiC whiskers (SiCws) and two-dimensional BN nanosheets (BNNS) nanoparticles were modified using modified layers formed by in-situ polymerization of PDA and PEI to obtain SiCws-BNNS@PDA-PEI heterostructure fillers with multifunctionality. Then, PEN-based composite films were fabricated by investigating different phase species and filling ratios. The results show that thermal conductivity of multi-component PEN/SiCws-BNNS@PDA-PEI (2.92 W/m.K) composite is 189.11 % higher than that of pure PEN, and coefficient of friction (0.17) and specific wear rate (1.28 × 10<sup>−5</sup> mm<sup>3/</sup>(N.m) are 45.16 % and 87.57 % lower than pure PEN respectively. And, correlation between thermal and friction behavior is explained.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"194 ","pages":"Article 108888"},"PeriodicalIF":8.1,"publicationDate":"2025-03-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143748069","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Guangqing Ming , Mingming Xu , Fengfeng Li , Chengjun Zeng , Wei Zhao , Liwu Liu , Yanju Liu , Jinsong Leng
{"title":"Effects of woven textures on the mechanical and shape memory properties of epoxy-based shape memory polymer composites","authors":"Guangqing Ming , Mingming Xu , Fengfeng Li , Chengjun Zeng , Wei Zhao , Liwu Liu , Yanju Liu , Jinsong Leng","doi":"10.1016/j.compositesa.2025.108885","DOIUrl":"10.1016/j.compositesa.2025.108885","url":null,"abstract":"<div><div>Woven fabrics are widely employed to enhance the mechanical properties and shape memory performance of shape memory polymers (SMPs). Although prior research has extensively investigated the effects of fiber fraction and laminate architectures on the thermomechanical properties of woven fabric reinforced shape memory polymer composites (WFR-SMPCs), the mechanistic understanding of mesoscale architectural features, particularly how woven textures influence the mechanical properties and shape memory behavior of SMPCs, remains inadequately explored. This investigation pioneers a mesostructure-driven design paradigm, correlating woven textures with shape memory anisotropy through mechanical testing and shape memory performance test. Three types of WFR-SMPCs were created using different woven carbon fiber fabrics (plain, twill, and satin) combined with an epoxy-based SMP. Microstructure analyses of these fabrics and their composites were performed. Uniaxial tensile tests explored the mechanical behavior and failure mechanisms of WFR-SMPCs in both fixed and programmable states, thereby assessing the impact of different woven textures on their mechanical properties. Additionally, bending deformation-recovery experiments assessed the shape memory performance, revealing how weave texture influences this characteristic. The experimental results indicated that woven fabric reinforcement markedly improves the mechanical properties of SMP. Variations in tow interlacing across weave types led to differing mechanical properties and shape memory performance in both (0/90) and (±45) orientations. This research offers critical insights for optimizing the design and application of WFR-SMPCs in engineering contexts.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"194 ","pages":"Article 108885"},"PeriodicalIF":8.1,"publicationDate":"2025-03-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143734533","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Stochastic multi-scale modeling for estimating the Mode-I dynamic fracture toughness of CNT-reinforced polymers","authors":"Reza Yazdanparast, Roham Rafiee","doi":"10.1016/j.compositesa.2025.108882","DOIUrl":"10.1016/j.compositesa.2025.108882","url":null,"abstract":"<div><div>A stochastic hierarchical multiscale model is developed to estimate the Mode-I dynamic fracture toughness of CNT-reinforced polymers, capturing both processing-induced inconsistencies and strain rate effects. At the nanoscale, molecular dynamic simulations of CNT pull-out from the matrix are performed to analyze the CNT-polymer interfacial properties at various pull-out speeds. At the microscale, a rate-dependent finite element model is established to characterize the pull-out profiles for different CNT lengths, orientations, and waviness at various pull-out speeds. Then, the CNT bridging phenomenon along the crack growth path is modeled considering viscoelastic-viscoplastic behavior for the matrix. The influence of CNT lengths, waviness patterns, orientations, and volume fractions at the microscale, as well as CNT agglomeration effects at the mesoscale, on critical fracture energy (G<sub>ID</sub>) are determined. At the macroscale, stochastic simulation is performed to estimate G<sub>ID</sub> treating involved uncertainties as random variables. Predicted results are in very good agreement with experimental observations.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"194 ","pages":"Article 108882"},"PeriodicalIF":8.1,"publicationDate":"2025-03-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143715395","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Junru Li , Weiyi Kong , Weijie Zhang , Yiding Li , Xuan Zhang , Shibo Yan
{"title":"Biaxial bending failure behavior of laminated composite plates under ring-on-ring loading: Effect of layups and interactive terms in failure criteria","authors":"Junru Li , Weiyi Kong , Weijie Zhang , Yiding Li , Xuan Zhang , Shibo Yan","doi":"10.1016/j.compositesa.2025.108883","DOIUrl":"10.1016/j.compositesa.2025.108883","url":null,"abstract":"<div><div>This study investigates the biaxial bending failure behavior of laminated composites, through ring-on-ring loading as described by the ASTM C1499 standard, originally developed for isotropic materials. Cross-ply and quasi-isotropic layups of two thicknesses were tested to assess failure mechanism under layup effect. Thin plates exhibited pronounced nonlinear stiffness across different layups while differences diminished in thick laminates. A numerical model employing the recently formulated Fully Rationalized Tsai-Wu failure criterion and further extending the criterion to identify failure modes to facilitate property degradation is developed for failure prediction under multiaxial stress states, aligning well with experimental results without requiring fitting model parameters. The inclusion of interactive terms in the criterion successfully captured multiaxial failure compared to non-interactive ones. Further stress analysis indicates the ASTM C1499 standard is not entirely applicable to laminates regarding equibiaxial flexural strength but highlights its potential for biaxial tensile testing of unidirectional laminates under non-equal stress ratios.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"194 ","pages":"Article 108883"},"PeriodicalIF":8.1,"publicationDate":"2025-03-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143725624","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"An improved progressive damage model for three-dimensional five-directional braided composites under longitudinal compression","authors":"Shaofeng Tang , Kunkun Fu , Yan Li","doi":"10.1016/j.compositesa.2025.108880","DOIUrl":"10.1016/j.compositesa.2025.108880","url":null,"abstract":"<div><div>Various failure modes of three-dimensional five-directional braided composites (3D5DBCs) under longitudinal compression have been observed, including yarn fracture and kinking, transverse inter-fiber cracking, matrix plastic deformation/fracture and fiber/matrix interfacial debonding, leading to the difficulty in predicting their mechanical properties. This study proposes an improved progressive damage model for 3D5DBCs under longitudinal compression, addressing all the observed failure modes. Then, the proposed progressive damage model is implemented in a finite element (FE) model to predict the mechanical responses and properties of 3D5DBCs under longitudinal compression. The numerical predictions in terms of compressive stress–strain relations, compressive strengths and failure modes are in good agreement with the experimental results, demonstrating the effectiveness of the proposed progressive damage model. Finally, the failure envelopes of 3D5DBCs under compression-shear loading are predicted using our FE model, and the effectiveness of several classical failure criteria on the strength prediction of 3D5DBCs is discussed.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"194 ","pages":"Article 108880"},"PeriodicalIF":8.1,"publicationDate":"2025-03-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143734535","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}