{"title":"Micro-nano diamond reinforced phenolic-derived carbon composites: Promoted structural evolution and performance","authors":"Chaoyang Zhang, Yanhui Wang, Shengyao Su, Menghui Zhao, Lixiang Zhao, Lezhu Zhang, Mingyang Dong, Jianbing Zang","doi":"10.1016/j.compositesa.2025.109254","DOIUrl":"10.1016/j.compositesa.2025.109254","url":null,"abstract":"<div><div>Glassy carbon with a curved fullerene-like structure, derived from thermosetting resin, holds great promise as bonding material for diamond grinding wheels particularly in dry grinding applications. In this study, a novel sp<sup>2</sup> carbon bonded micro-nanodiamond (MND) composite was fabricated using phenolic resin (PR) as the carbon bond precursor. The influence of MND on the pyrolysis behavior of PR and the evolution of the carbon structure below 1000 ℃ was systematically investigated. Results showed that MND promoted the decomposition of methylene bridges and phenolic hydroxyl groups, thereby facilitating the formation of curved carbon layers and fullerene-like structures in the PR-derived carbon. Additionally, smaller MND grit sizes significantly enhanced the bending strength and wear resistance of the composites, which was attributed to improved interfacial bonding and the catalytic effect of diamond in forming a more ordered carbon structure. These findings offer important guidance for the rational design of high-performance carbon-bonded diamond grinding wheels and shed new light on the advancement of dry grinding technologies in semiconductor processing.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"199 ","pages":"Article 109254"},"PeriodicalIF":8.1,"publicationDate":"2025-08-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144879525","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":"Unravel the nature of interface bonding and self-healing in vitrimer-carbon fiber composites","authors":"Tanaya Mandal , Morteza Ghanbarian , Unal Ozten , Mohammad Naraghi","doi":"10.1016/j.compositesa.2025.109253","DOIUrl":"10.1016/j.compositesa.2025.109253","url":null,"abstract":"<div><div>Fiber–matrix interfacial load transfer in carbon fiber polymer matrix composites (CFRP) is crucial to the composite’s mechanical performance. In this study, we investigated the intrinsic self-healing capability of the vitrimer–carbon fiber (CF) interface, specifically examining whether thermoset matrices with adaptive covalent networks can restore interfacial properties at the fiber–matrix scale. Using pull-out tests, we demonstrated that a high-performance vitrimer matrix (ATSP) enables exceptional recovery of interfacial shear strength (IFSS), achieving up to 97.2 % restoration following healing. The structural integrity of the interface was confirmed through optical microscopy and consistent contact angle measurements between as-received and healed samples. To identify the mechanisms of adhesion and self-healing, we removed approximately 60 % of the surface functional groups from CFs via high-temperature desizing, as verified by XPS, which resulted in a ∼ 12 % reduction in IFSS. This outcome indicates that chemical bonding may contribute up to 20 % of the load-bearing capacity, while van der Waals (vdW) interactions and mechanical interlocking dominate the load transfer between fiber and vitrimer. The local flow of vitrimer, facilitated by the bond exchanges, seems to be the driving mechanism for re-forming intimate contact between fibers and matrix, as required to re-establish the load transfer. SEM analysis revealed adhesive failure at the vitrimer–CF interface as the primary failure mode. Overall, these findings establish the self-healing potential of vitrimer–CF interfaces and provide valuable insight into the mechanisms governing interfacial recovery in advanced composites.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"199 ","pages":"Article 109253"},"PeriodicalIF":8.1,"publicationDate":"2025-08-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144864431","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}
Tianyu Wang , Xiaoliang Liang , Bing Wang , Kexian Liu , Tianxiang Li , Yukui Cai , Zhanqiang Liu
{"title":"Ultrasonic vibration-assisted machining in aerospace composite materials: Principle, technology, challenges","authors":"Tianyu Wang , Xiaoliang Liang , Bing Wang , Kexian Liu , Tianxiang Li , Yukui Cai , Zhanqiang Liu","doi":"10.1016/j.compositesa.2025.109250","DOIUrl":"10.1016/j.compositesa.2025.109250","url":null,"abstract":"<div><div>Advanced composite materials are widely used in key aerospace components due to the excellent characteristics of exceptional strength-to-weight ratios, corrosion resistance, fatigue resistance, etc. Conventional machining (CM) easily causes surface defects due to the uncontrolled material tear and severe thermal–mechanical loads. Ultrasonic vibration-assisted machining (UVAM) by introducing periodic high-frequency separation results in surface defects suppression, thermal damage reduction decreasing, and tool wear decreasing. This work reviews the frontier progress and innovation trends of the UVAM aerospace composite materials, involving the equipment and technology innovation, the characteristics and theory, and the material removal mechanisms. Firstly, the equipment and motion trajectory analysis of UVAM are systematically reviewed, involving the one-dimensional, the two-dimensional, and the three-dimensional UVAM with trajectory evaluations. Secondly, the advantaged characteristics of UVAM are analyzed, involving the intermittent contact, the multi-stage elastic–plastic deformation, the shear sharpening impact, and the friction reverse. Then, the dynamic time-varying evolution of the multi-physical fields are discussed including the heat generation/transfer, the stress, and the strain during UVAM composite materials. Subsequently, the influence mechanisms and response consequences for UVAM composite materials are analyzed involving tool wear, chip formation, and surface quality. Ultimately, the key points of UVAM technology in terms of theory, characteristics, mechanism and application are summarized and the frontier challenges and future pathways toward high-efficiency/high-precision UVAM are mapped to guide next-generation aerospace manufacturing. This review provides important reference for engineering applications for UVAM aerospace composites.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"199 ","pages":"Article 109250"},"PeriodicalIF":8.1,"publicationDate":"2025-08-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144886781","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}
Zemin Ji, Xiaobin Huang, Xiangzhao Wang, Haoqiang Sheng, Shiyu Xu
{"title":"Mechanical sintered solid/liquid interpenetrating conductive network for aircraft icing protection and real-time temperature monitoring","authors":"Zemin Ji, Xiaobin Huang, Xiangzhao Wang, Haoqiang Sheng, Shiyu Xu","doi":"10.1016/j.compositesa.2025.109237","DOIUrl":"10.1016/j.compositesa.2025.109237","url":null,"abstract":"<div><div>The complex environment of ice formation and electromagnetic interference severely impairs the normal functioning of aircraft components. Conventional aircraft electric heating elements suffer from a lack of real-time temperature monitoring of heating and are prone to electromagnetic interference during operation. Therefore, the development of an aircraft outer protected surface film with both temperature monitoring and electromagnetic shielding functions is of great significance. In this work, a dual-layer solid/liquid interpenetrating conductive network composite film was designed, with local mechanical sintered liquid metal (LM)/silicon carbide as the upper-layer coating and comprehensive mechanical sintered LM/PEDOT/fabric as the conductive substrate. Benefiting from the combined effect of the upper surface coating with a thermal conductivity of 1.48 W/mK and the underlying substrate with an electrical conductivity of 1.1 × 10<sup>3</sup> S/m, the composite coating exhibits excellent electrothermal de-icing and temperature monitoring performance. The composite film, with its outstanding Joule heating characteristics, reaching 89.4 °C within 60 s at a low voltage of 3 V and has the capability of static and dynamic de-icing in −15 ℃ environments. The composite film, with its electromagnetic shielding capability of 37.9 dB at 8.2–12.4 GHz (X-band) and flexibility, can provide electromagnetic protection for the entire wing. This work pioneers a material-level solution for the design of a new-generation aircraft electric heating system.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"199 ","pages":"Article 109237"},"PeriodicalIF":8.1,"publicationDate":"2025-08-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144864430","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}
Caleb Beckwith, Juan Fadhel, Andrew Park, Nikhil Gupta
{"title":"Rheology guided additive manufacturing of thermosetting syntactic foams: mechanical behavior and failure mechanisms","authors":"Caleb Beckwith, Juan Fadhel, Andrew Park, Nikhil Gupta","doi":"10.1016/j.compositesa.2025.109248","DOIUrl":"10.1016/j.compositesa.2025.109248","url":null,"abstract":"<div><div>Hollow glass microspheres (HGMs) are reinforced in an acrylate-based photopolymer resin to develop a digital light processing based additive manufacturing (AM) method for fabricating composites called syntactic foams. Extrusion based AM methods have been developed for thermoplastic syntactic foams, but inherent challenges have prevented researchers from making progress in developing AM methods for thermosetting resin matrix syntactic foams. Rheological analysis guided the optimal printing temperatures to maintain flow consistency across mixture compositions during manufacturing. Stirring the mixture during printing proved essential for mitigating particle flotation, which is a major issue in syntactic foam manufacturing due to the density difference between particles and the matrix. Mechanical testing revealed that compressive performance benefited significantly from in-situ mixing, with compressive modulus increasing with HGM volume fraction. Micro-computed tomography confirmed particle distribution and porosity trends, while microscopy illustrated the transition from matrix-dominated to particle-dominated fracture behavior with increasing filler content.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"199 ","pages":"Article 109248"},"PeriodicalIF":8.1,"publicationDate":"2025-08-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144852761","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":"Intrinsic mechanism, preparation and application of noise reduction polymer-based composites for aviation noise: A mini-review","authors":"Zheng Liu , Ruihan Zhang","doi":"10.1016/j.compositesa.2025.109246","DOIUrl":"10.1016/j.compositesa.2025.109246","url":null,"abstract":"<div><div>With the development of the aviation industry, noise levels have become a key factor affecting aircraft comfort. Aircraft noise mainly consists of aerodynamic, structural vibration, and engine noise, each with unique intensity and frequency characteristics that differ from those in traditional building and rail transit. Thus, common noise-reduction materials like foams and fiber felts are no longer sufficient for future civil aircraft and propulsion systems. A major research direction in polymer-based composites focuses on designing material structures and understanding how microstructural features influence macroscopic noise-reduction performance. Moreover, applying advanced polymer composites to aircraft panels, engine nacelle liners, and other critical parts offers a promising way to reduce noise at the source, supporting overall noise control in next-generation aircraft, which is a central goal in current civil aviation research. This review first discusses the sources, hazards, and mechanisms of aviation noise, then introduces the classification and evaluation methods of s noise reduction polymer-based composites. It also summarizes recent global progress and trends in sound-insulation and sound-absorbing composites. Finally, it highlights advances in high-performance, multifunctional noise-reduction polymer-based composites and outlines future directions for aerospace acoustic materials.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"199 ","pages":"Article 109246"},"PeriodicalIF":8.1,"publicationDate":"2025-08-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144858238","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}
Adarsh Kumar Shah , Arnab Palit , Mark A. Williams , Paul F. Wilson , Atul Jain
{"title":"Microstructural alteration and its impact on the effective stiffness of short carbon fiber-reinforced PLA in fused deposition modeling","authors":"Adarsh Kumar Shah , Arnab Palit , Mark A. Williams , Paul F. Wilson , Atul Jain","doi":"10.1016/j.compositesa.2025.109229","DOIUrl":"10.1016/j.compositesa.2025.109229","url":null,"abstract":"<div><div>This study investigates the change in microstructure of short carbon fiber-reinforced polylactic acid (CF-PLA) filaments during fused deposition modeling (FDM) printing and its impact on the effective elastic modulus of printed parts. A comprehensive experimental protocol is employed, including thermogravimetric analysis (TGA), photomicrography, and micro-computed tomography (µ-CT) to characterize key microstructural parameters such as fiber volume fraction, aspect ratio, and fiber orientation distribution. Additionally, uniaxial tensile tests are performed on specimens printed in three raster orientations (<em>0°</em>, <em>±45°</em>, and <em>90°</em>) to characterize mechanical response. The experiments reveal significant fiber misalignment, fiber breakage, and matrix degradation during FDM printing, all contributing to a substantial reduction in Young’s modulus.</div><div>To interpret the experimental observations, two novel tri-scale homogenization models (Mori-Tanaka-Finite Element and Fully Finite Element) were developed, integrating micro-, meso-, and macro-scale data to predict effective stiffness with errors below 5% and 7%, respectively, across various raster orientations. A key innovation in this framework is the introduction of a degradation parameter to account for matrix deterioration during printing. Parametric studies identified fiber breakage as the most significant factor, causing a 27.15% stiffness loss, followed by misalignment (15.54%) and matrix degradation (10.74%). This holistic framework, combining experimental and computational approaches, elucidates process-structure–property relationships, offering a new insights about FDM-printed short fiber-reinforced composites for structural applications.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"199 ","pages":"Article 109229"},"PeriodicalIF":8.1,"publicationDate":"2025-08-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144858236","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":"Preparation and performance of high-efficiency photothermal multifunctional self-healing polyurethane coating based on MoS2@CuS@ZIS ternary heterojunction and double dynamic covalent bond","authors":"Xin Wang, Xinwei Zhang, Wen Li, Wei Wang, Jie Zhu, Shougang Chen","doi":"10.1016/j.compositesa.2025.109242","DOIUrl":"10.1016/j.compositesa.2025.109242","url":null,"abstract":"<div><div>Marine equipment is confronted with multiple threats such as corrosion, low-temperature freezing and microbial fouling. Therefore, it is necessary to develop multi-functional protective coatings. In this study, the wear resistance, anti-fouling, photothermal, electromagnetic wave absorption, defrosting and deicing, and long-lasting anti-corrosion performance of modified polyurethane (PU) coating were improved by incorporating MoS<sub>2</sub>@CuS@ZIS ternary heterojunctions. The results show that the coating still maintains good corrosion resistance after being soaked for 90 days. The built-in electric field of the ternary heterostructure promotes the non-radiative recombination of electrons and holes, thereby enhancing the efficiency of photothermal conversion. In addition, with the dual dynamic covalent bonds of carbamate and oxime, the coating has a rapid self-healing performance. Defrosting and deicing under light can be completed within 130 s. In addition, the highly efficient catalytic performance of the S-type heterojunction, in synergy with Cu<sup>2+</sup> ions, endows the coating with excellent antibacterial properties. The incorporation of filling materials has increased the wear resistance by 34 %. This work has important participation value for the research and development of new multifunctional PU coatings.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"199 ","pages":"Article 109242"},"PeriodicalIF":8.1,"publicationDate":"2025-08-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144852760","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}
Ali Moghimi-ardekani, Jianqun Hao, Jan Ivens, Aart Willem van Vuure
{"title":"Hygroscopic effect on fatigue behaviour of natural fibre reinforced thermoset and thermoplastic composites","authors":"Ali Moghimi-ardekani, Jianqun Hao, Jan Ivens, Aart Willem van Vuure","doi":"10.1016/j.compositesa.2025.109244","DOIUrl":"10.1016/j.compositesa.2025.109244","url":null,"abstract":"<div><div>This study evaluates the fatigue performance of various thermoset and thermoplastic composites reinforced with unidirectional flax fibre under hygroscopic conditions. Quasi-static testing was conducted to assess the impact of humidity on the mechanical modulus of these composites. The flexural and tensile testing results revealed that, at higher humidity levels (85%<!--> <!-->RH) compared to standard conditions (50%<!--> <!-->RH), flexural modulus exhibits a stronger drop than tensile modulus, likely due to compressive deformation. Moreover, the flax fibre composites incorporating thermoset matrices, including epoxy and partially bio-based unsaturated polyester, demonstrate a shorter fatigue life at 85%<!--> <!-->RH relative to 50%<!--> <!-->RH. In contrast, thermoplastic-based flax fibre composites, such as with POM, PA11, and MAPP matrices, show improved fatigue resistance as humidity increases from 50%<!--> <!-->RH to 85%<!--> <!-->RH. These findings are supported by creep tests, which reveal an increase in the creep lifespan of thermoplastic composites at higher humidity. Furthermore, the fatigue data reveal that residual strain, loss factor, and hysteresis energy increase with increasing humidity. Stiffness during fatigue diminishes at 85%<!--> <!-->RH compared to 50%<!--> <!-->RH, but it doesn’t degrade during the cycling.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"199 ","pages":"Article 109244"},"PeriodicalIF":8.1,"publicationDate":"2025-08-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144858237","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}
Chuanbiao Zhu , Xinpeng Hu , Wenling Wang , Xiangyu Yan , Shenglong Xiao , Zhigang Liu , Xiang Lu , Jinping Qu
{"title":"Nervous system inspired interconnected phase change composites with efficient thermal conductive network for sustained power generation","authors":"Chuanbiao Zhu , Xinpeng Hu , Wenling Wang , Xiangyu Yan , Shenglong Xiao , Zhigang Liu , Xiang Lu , Jinping Qu","doi":"10.1016/j.compositesa.2025.109243","DOIUrl":"10.1016/j.compositesa.2025.109243","url":null,"abstract":"<div><div>Phase change composites (PCCs) have become pivotal in advanced thermal energy storage (TES) systems, showing promise in addressing the intermittency of renewable energy sources. However, reconciling the tripartite challenge of achieving high enthalpy, phonon transport enhancement and flexible skeleton is still a grand challenge. Herein, a flexible boron nitride (BN)/ carbon nanotube (CNT)/ cellulose nanofiber (CNF) aerogel is prepared through synergistic non-covalent and covalent interfacial engineering, BCF aerogel achieves exceptional resilience (96% compressive strength retention after 50% compression rebound) and effectively encapsulates polyethylene glycol (90.9 wt% loading) with minimal leakage (1.5 wt% losses after 200 thermal cycles). The BCF@PEG PCCs features a unique 3D fibrous “thermal track” structure inspired by neural signal pathways, wherein the BN nanosheets are densely assembled in a face-to-face configuration along the surface of CNF bundles, CNT-COOH bridged the gaps between BN sheets. The core-sheath architecture significantly mitigates interfacial thermal resistance while achieving an unprecedented thermal conductivity enhancement efficiency of 69.9% wt<sup>−1</sup>%, outperforming conventional blending methods by over 17-fold. Notably, the BCF@PEG-integrated thermoelectric module exhibit uninterrupted power generation under intermittent solar irradiation through adaptive phase-change regulation. This method provides a scalable paradigm for designing multifunctional BN-based PCCs toward sustainable energy infrastructure.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"199 ","pages":"Article 109243"},"PeriodicalIF":8.1,"publicationDate":"2025-08-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144861168","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}