Composites Part A: Applied Science and Manufacturing最新文献

{"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}

{"title":"Fiber orientation and porosity in large-format extrusion process: The role of processing parameters","authors":"Segun Isaac Talabi ,&nbsp;Komal Chawla ,&nbsp;Brittany Rodriguez ,&nbsp;Abdallah Barakat ,&nbsp;Yalcin Meraki ,&nbsp;Akash Phadatare ,&nbsp;Marco Brander ,&nbsp;Berin Šeta ,&nbsp;Jon Spangenberg ,&nbsp;H. Felix Wu ,&nbsp;Uday Vaidya ,&nbsp;Vlastimil Kunc ,&nbsp;Ahmed Arabi Hassen ,&nbsp;Vipin Kumar","doi":"10.1016/j.compositesa.2025.108891","DOIUrl":"10.1016/j.compositesa.2025.108891","url":null,"abstract":"<div><div>Controlling fiber orientation and porosity in short-fiber thermoplastic composites is important for enhancing mechanical, electrical and thermal properties in large-format additive manufacturing. This study employs a factorial design of experiments (DoE) to assess the effects of nozzle diameter (5.08 mm–10.16 mm), temperature (230–250 °C), and extruder screw speed (150–280 rpm) on flow rate, shear rate, porosity, fiber orientation, fiber length and tensile strength in 20 % carbon fiber-filled acrylonitrile butadiene styrene. ANOVA results show that screw speed significantly impacts flow rate, while nozzle diameter and temperature have lesser effects. Shear rate increases with smaller nozzles and higher speeds. Porosity decreases from 5.58 % with a 10.16 mm nozzle to 3.11 % with a 5.08 mm nozzle at 150 rpm due to increased shear rates, which induce shear thinning, reducing viscosity and facilitating gas escape. Larger nozzles (10.16 mm) produce larger, more heterogeneous pores, while smaller nozzles (5.08 mm) yield smaller, uniform pores. Beads produced with the 5.08 mm nozzle exhibit longer fiber lengths due to reduced residence time, lower shear stress, and better alignment. Fiber orientation improves with smaller nozzles due to higher shear rates but decreases with higher screw speeds (280 rpm) due to shorter residence times. The highest fiber alignment (A_xx ∼ 0.65) and low porosity (∼3%) were achieved with a 5.08 mm nozzle at 150 rpm, while equivalent additive manufacturing-compression molding samples exhibited better tensile strength (∼93 MPa) under these conditions. These findings emphasize the importance of optimizing processing parameters to enhance fiber alignment and reduce porosity for improved mechanical performance.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"194 ","pages":"Article 108891"},"PeriodicalIF":8.1,"publicationDate":"2025-03-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143759513","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":"Boosting thermal conductivity and tribological performance of polyarylene ether nitrile synergistically by fabricating SiCws-BNNS multidimensional networks","authors":"Liang He ,&nbsp;Jinghui Zhang ,&nbsp;Yu Zheng ,&nbsp;Shuning Liu ,&nbsp;Xiaobo Liu ,&nbsp;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 × 10⁻⁵ mm^3/(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}

{"title":"Rapid out-of-oven lamination (ROL) for energy-efficient manufacturing of carbon fiber reinforced composites","authors":"Arif M. Abdullah ,&nbsp;Michael Zakoworotny ,&nbsp;Conan Zhang ,&nbsp;Philippe H. Geubelle ,&nbsp;Jeffery W. Baur","doi":"10.1016/j.compositesa.2025.108873","DOIUrl":"10.1016/j.compositesa.2025.108873","url":null,"abstract":"<div><div>Traditional composite manufacturing typically involves batch processing with long curing cycles in capital-intensive equipment to achieve composites that are constrained to be less than the size of the mold or oven. Here, we report a rapid out-of-oven lamination (ROL) process for energy-efficient and continuous manufacturing of carbon fiber (CF) reinforced composite laminates. The energy efficiency of our process stems from the combination of two distinct features: (i) the direct and simultaneous application of cure-initiating thermal energy and compaction pressure via hot rollers, and (ii) the resulting rapid through-thickness bulk polymerization of CF prepregs infused with catalyzed dicyclopentadiene (DCPD). We investigate the effects of roller speed, temperature, and pressure on the degree of cure and compare the experimentally observed thermal evolution of the laminates with a thermo-chemical computational model. We demonstrate the applicability of our process to CF-based prepregs through rapid manufacturing of unidirectional, cross-ply, and fabric laminates. The resulting composites have high CF volume fractions, low void fractions, and flexural moduli that approach predictions made by Classical Laminate Theory. Composites that are three times longer than the fabricator are manufactured to demonstrate that dimensions are not limited by the size of the processing equipment. The ROL process is estimated to require two orders of magnitude less curing energy by volume and to be significantly less time-intensive than traditional processes. Overall, the rapid, energy-efficient, and continuous nature of the ROL process makes it a good candidate for manufacturing high-quality structural composites in environments constrained by available energy or fabricator size.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"194 ","pages":"Article 108873"},"PeriodicalIF":8.1,"publicationDate":"2025-03-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143785447","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":"Effects of woven textures on the mechanical and shape memory properties of epoxy-based shape memory polymer composites","authors":"Guangqing Ming ,&nbsp;Mingming Xu ,&nbsp;Fengfeng Li ,&nbsp;Chengjun Zeng ,&nbsp;Wei Zhao ,&nbsp;Liwu Liu ,&nbsp;Yanju Liu ,&nbsp;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":"Preface: Machine learning and AI in composite science and manufacturing","authors":"","doi":"10.1016/j.compositesa.2025.108890","DOIUrl":"10.1016/j.compositesa.2025.108890","url":null,"abstract":"","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"193 ","pages":"Article 108890"},"PeriodicalIF":8.1,"publicationDate":"2025-03-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143791756","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":"Orthotropic elastic constants and tensile strength of extrusion-based additively manufactured carbon/carbon composites after polymer infiltration and pyrolysis","authors":"Edwin S. Romero ,&nbsp;Bryant Burton ,&nbsp;Ashley Hilmas ,&nbsp;Eduardo Barocio ,&nbsp;Rodney W. Trice","doi":"10.1016/j.compositesa.2025.108884","DOIUrl":"10.1016/j.compositesa.2025.108884","url":null,"abstract":"<div><div>This study was aimed at obtaining orthotropic elastic constants and tensile strengths of extrusion-based additively manufactured (EDAM) carbon/carbon (C/C) composites. Micro-computed tomography (µCT) data was coupled with impulse excitation data and Mori-Tanaka homogenization- based microstructural modeling to analyze 50 wt% short carbon fiber-loaded polyphenylene sulfide (PPS)-based C/C composites. After five polymer infiltration and pyrolysis cycles, the elastic constants and average tensile strength were found to be E₁ = 30.48 GPa, E₂ = 17.85 GPa, E₃ = 12.34 GPa, G₂₃ = 5.57 GPa, G₁₃ = 6.65 GPa, G₁₂ = 9.19 GPa, ν₂₃ = 0.28, ν₁₃ = 0.25, ν₁₂ = 0.26, and σ_T = 12.71 MPa, respectively. The results were unique to the fiber orientation induced during 3D printing and pore volume fraction achieved with densification and highlights the Mori-Tanaka- based microstructural modeling as a beneficial tool for capturing the fiber architecture- and process- dependent behavior of C/C composites.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"194 ","pages":"Article 108884"},"PeriodicalIF":8.1,"publicationDate":"2025-03-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143829124","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,&nbsp;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_ID) are determined. At the macroscale, stochastic simulation is performed to estimate G_ID 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}