Composites Part A: Applied Science and Manufacturing最新文献

{"title":"Glass fiber-reinforced epoxy composites with high thermal conductivity, flame retardancy and mechanical strength","authors":"Ze-Tao Xiao ,&nbsp;Hao-Jie Shi ,&nbsp;Wei Wang ,&nbsp;Qun Liu ,&nbsp;Yu Li ,&nbsp;Yuan Hu ,&nbsp;Xin Wang","doi":"10.1016/j.compositesa.2025.108905","DOIUrl":"10.1016/j.compositesa.2025.108905","url":null,"abstract":"<div><div>Fiber-reinforced epoxy resins (FREPs) have shown broad application prospects because of their excellent comprehensive properties, but their poor thermal conductivity and lack of flame retardancy also restrict their usage in many fields. To solve these problems, DOPO-GL-DCDA was selected as a flame retardant, tannic acid-modified BN and Al₂O₃ were selected as fillers to improve the thermal conductivity of the epoxy thermosets simultaneously, and glass fiber-reinforced epoxy composites (GFREPs) were subsequently prepared by combining an epoxy-filler system with glass fibers (GFs) or modified glass fibers (mGFs). The obtained GFREP revealed excellent comprehensive properties, including flame retardancy, thermal conductivity and mechanical properties. Specifically, the thermal conductivities of EP/40 %(Al₂O₃ + BN)/GF and EP/40 %(Al₂O₃ + BN)/mGF were 0.638 and 0.609 W·m⁻¹·K⁻¹, respectively. Additionally, EP/40 %(Al₂O₃ + BN)/mGF had an LOI of 56.0 % and a V-0 rating in the UL-94 vertical burning test. Compared with those of EP, the heat release rate (HRR), total heat release (THR) and total smoke production (TSP) of EP/40 %(Al₂O₃ + BN)/mGF were reduced by 90.9 %, 90.6 % and 80.2 %, respectively. Moreover, the mechanical properties, including the tensile and impact strengths, of EP/40 %(Al₂O₃ + BN)/mGF reached 239.2 MPa and 77.4 kJ/m², respectively. In summary, the prepared GFREP combines a series of excellent comprehensive properties with the maintenance of low dielectric loss, which shows wide potential in electronic and electrical applications.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"194 ","pages":"Article 108905"},"PeriodicalIF":8.1,"publicationDate":"2025-04-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143785534","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":"Regulating SiO2 interlayer morphology towards synergistically reinforced dielectric properties and thermal conductivity in Si/PVDF composites","authors":"Mengyuan Zhang ,&nbsp;Wenying Zhou ,&nbsp;Yanqing Zhang ,&nbsp;Fanrong Kong ,&nbsp;Xiaolong Chen ,&nbsp;Fang Wang ,&nbsp;Jian Zheng ,&nbsp;Shaolong Zhong","doi":"10.1016/j.compositesa.2025.108893","DOIUrl":"10.1016/j.compositesa.2025.108893","url":null,"abstract":"<div><div>Polymeric composites integrating large dielectric constant (<em>ε</em>), minimal loss with elevated breakdown strength (<em>E</em>_b) and thermal conductivity (TC), exhibit concern in electrical and power industry. To enhance the TC and <em>E</em>_b while suppressing loss in silicon (Si)/poly (vinylidene fluoride, PVDF), the Si@silica (SiO₂) was prepared by high-temperature oxidation, and subsequently doped into PVDF. The Si@SiO₂/PVDF displays lower loss since the SiO₂ layer prevents direct contact between Si particles， inhibiting long-distance electron migration. Moreover, the SiO₂ introduces traps to immobilize charge carriers, elevating the <em>E</em>_b. In particular, changing the amorphous SiO₂ shell to crystalline one accelerates phonon transport, leading to enhanced TC. The dielectric parameters and TC of the Si@SiO₂/PVDF can be synergistically tuned by adjusting the SiO₂′ morphology and thickness. The theoretical calculation uncovers the underlying mechanisms for both charge and phonon transport in the composites. This developed Si@SiO₂/PVDF composites with excellent dielectric performances and large TC showcase widespread applications.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"194 ","pages":"Article 108893"},"PeriodicalIF":8.1,"publicationDate":"2025-04-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143785448","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":"Porosity evolution in additively manufactured compression molded short fiber thermoplastics under cyclic loading: Insights from micro-computed tomography and infrared thermography","authors":"Pharindra Pathak,&nbsp;Suhasini Gururaja","doi":"10.1016/j.compositesa.2025.108881","DOIUrl":"10.1016/j.compositesa.2025.108881","url":null,"abstract":"<div><div>Composite structures, integral to lightweight, high-performance applications, often suffer from premature fatigue failure due to process-induced defects such as porosity. The recently developed additive manufacturing and compression molding (AM-CM) process enables short fiber thermoplastics (SFTs) with greater fiber orientational control and low porosity. However, the existing pores in SFTs act as fatigue damage initiators, emphasizing the need for a better understanding of the effect of pores on the fatigue behavior of SFTs.</div><div>In this study, process defects in 20 wt% carbon fiber reinforced acrylonitrile butadiene styrene (C/ABS) SFTs produced through AM-CM were first identified using ultrasonic inspection and analyzed in detail via micro-computed tomography (<span><math><mi>μ</mi></math></span>-CT). A rapid fatigue testing approach was employed to characterize the cyclic degradation of SFTs, utilizing infrared thermography (IRT) to measure surface temperature changes induced by self-heating, combined with a staircase cyclic loading profile. Porosity evolution in AM-SFTs under cyclic loading was tracked by interrupting the test before the expected fatigue and post-fatigue limits for a precise correlation between defect progression and fatigue performance. The findings demonstrate that increased porosity significantly reduces fatigue resistance, while <span><math><mi>μ</mi></math></span>-CT reveals clustering near fiber ends and within fiber-rich zones as critical contributors to damage initiation. Numerical homogenization, incorporating <span><math><mi>μ</mi></math></span>-CT fiber and pore statistical data within an octree-based algorithm for microstructure generation, validated the experimental observations and provided insights into effective property degradation. This study establishes a robust framework for characterizing fatigue behavior in SFT composites, offering significant potential for improving predictive models and optimizing manufacturing processes to mitigate defects and enhance performance.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"194 ","pages":"Article 108881"},"PeriodicalIF":8.1,"publicationDate":"2025-04-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143799706","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":"Simultaneous enhancement of mechanical robustness and self-sensing performance in fly ash-based geopolymer nanocomposites","authors":"Hailong Hu ,&nbsp;Yefan Liu ,&nbsp;Lei Chen ,&nbsp;Fan Zhang","doi":"10.1016/j.compositesa.2025.108894","DOIUrl":"10.1016/j.compositesa.2025.108894","url":null,"abstract":"<div><div>The simultaneous enhancement of both mechanical robustness and self-sensing capabilities in geopolymer nanocomposites significantly advances the precision and dependability of structural health monitoring systems. In this study, the uniform dispersion of graphene nanoplatelets (GNPs) within fly ash-based geopolymer composites is successfully achieved through the in-situ chemical synthesis of a silica (SiO₂) coating on the GNP surface. The resulting composite material exhibits a significant enhancement in sensitivity, which is attributed to the presence of the SiO₂ coating on the GNPs. In comparison to uncoated GNP/geopolymer composites, varying the concentration of the precursor tetraethyl orthosilicate (TEOS) from 0 to 8 ml enables the formation of SiO₂ coatings with different thicknesses, which effectively modulates the resistivity of the composite to meet specific sensing application requirements. The self-sensing sensitivity of the composite shows a considerable increase of 479.7 %, accompanied by a concurrent 89.1 % increase in elastic modulus. Notably, the gauge factor (GF) of geopolymer composites reached up to 491, which surpasses the results reported in recent literatures. The underlying mechanism suggests the in-situ SiO₂ coating significantly enhances the composite’s sensitivity and mechanical properties by improving the interface bonding between GNP and the geopolymer matrix, acting as a dielectric layer to reduce direct contact and particle agglomeration, and exhibiting excellent chemical and thermal stability. This advancement holds paramount importance in mitigating risks associated with structural failures, prolonging the operational lifespan of critical infrastructure, and ultimately improving public safety standards.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"194 ","pages":"Article 108894"},"PeriodicalIF":8.1,"publicationDate":"2025-04-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143769169","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":"On residual tensile strength after lightning strikes","authors":"X. Xu ,&nbsp;S.L.J. Millen ,&nbsp;D. Mitchard ,&nbsp;M.R. Wisnom","doi":"10.1016/j.compositesa.2025.108899","DOIUrl":"10.1016/j.compositesa.2025.108899","url":null,"abstract":"<div><div>The study of post lightning strike residual strength is still relatively underdeveloped in the literature. Different approaches including in-plane compression or flexural testing have been used, but in-plane tensile loading post-strike has not been studied in detail. Although previous attempts have been made to determine the residual strength using Compression-After-Lightning (CAL) tests on composite laminates, these have been limited and not readily applicable under tensile loads. Therefore, this work completes Tension-After-Lightning (TAL) testing at 75 kA on composite laminates, a more realistic peak current than previously reported for TAL tests, to assess the knock-down in strength post-strike. The measured average TAL failure stress was 716 MPa, a reduction of 23 % from the baseline tensile failure stress of 929 MPa in the literature. This confirms a similar knock-down factor reported at lower peak currents (e.g. 50 kA), but the new TAL specimen geometry ensures that the lightning damage is contained within both the lightning and TAL specimen widths. In addition, a new Finite Element (FE) based virtual test was conducted, considering 0° ply splitting, and validated with the TAL tests herein. The TAL simulation predicted the residual tensile failure stress well, within 6 % of the measured value.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"194 ","pages":"Article 108899"},"PeriodicalIF":8.1,"publicationDate":"2025-03-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143785537","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Recent progress in non-planar 3D printing of continuous fiber-reinforced composites","authors":"Ping Cheng,&nbsp;Zhi Han,&nbsp;Yuan Chen,&nbsp;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}

{"title":"Low velocity impact response of carbon fiber reinforced thermoplastic composite honeycomb sandwich structure considering mesoscopic damage behavior","authors":"Yong-Zhang Huo ,&nbsp;Jin-Shui Yang ,&nbsp;Zhao Suo ,&nbsp;Tian Zhao ,&nbsp;Wei-Jing Wang ,&nbsp;Yao-Hui Tong ,&nbsp;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,&nbsp;Junxue Ren,&nbsp;Yali Zhang,&nbsp;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}

{"title":"Upcycling aluminum-plastic packaging waste into high thermal conductivity and fire safety composite","authors":"Yixuan Cao ,&nbsp;Siming Shen ,&nbsp;Liang Li ,&nbsp;Dawei Luo ,&nbsp;Xiaotong Wang ,&nbsp;Fujie Wang ,&nbsp;Zhepeng Di ,&nbsp;Enhui Liu ,&nbsp;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 (S³M). 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}

{"title":"Comparative investigation exploring the role of carbonization features on the ablation behavior of graphite/phenolic and pitch/phenolic composites","authors":"Yisen Huang,&nbsp;Haoruo Zhang,&nbsp;Chuxiang Zhou,&nbsp;Jingfeng Tian,&nbsp;Hao Zhang,&nbsp;Liwei Yan,&nbsp;Huawei Zou,&nbsp;Yang Chen,&nbsp;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}