A novel method for through-thickness reinforcement of laminated composites using discrete micro-polarization-induced fiber injection (DMFI) approach

Conventional through-thickness reinforcement methods for laminated composites, such as Z-pin, encounter issues with in-plane property degradation and complex fabrication processes. To achieve rapid and low-damage reinforcement, a novel approach using short-chopped carbon fibers (SCFs) to form a micron-diameter interlaminate structure has been proposed. This method employs a discrete micro-polarization-induced fiber injection (DMFI) technique, where polarized SCFs are electrostatically oriented and injected at high speeds into pre-formed holes in the laminates. The insertion process of SCFs was thoroughly investigated, with optimal interlaminate conditions determined using high-speed cameras and other equipment. The toughening mechanism of SCFs was explored through various characterization methods, including metallurgical microscopy. This innovative method offers several advantages over the traditional Z-pin reinforced method. Notably, present method eliminates the need for prefabrication of Z-pins and fully leverages the excellent mechanical properties of individual carbon fiber in short length. It provides superior interlaminar mechanical properties, achieving a 392 % improvement compared to the control group and a 15 % improvement compared to 0.1 mm Z-pin reinforcement at the same insertion volume fraction. Additionally, it has minimal impact on the in-plane properties of the laminates, with only a 3.6 % reduction in tensile strength and a 4.1 % reduction in compression strength. Furthermore, it is environmentally friendly, allowing for the recycling and reuse of waste SCFs.