Search Results (192)

The effects of ultraviolet (UV) light and moisture environments on the properties of continuous fiber-reinforced thermoplastic composites were investigated in this study. Materials included carbon fiber-reinforced polyphenylene sulfide (CF/PPS), glass fiber-reinforced polyphenylene sulfide (GF/PPS), glass fiber-reinforced polypropylene (GF/PP), and glass fiber-reinforced polyethylene terephthalate (GF/PET). Fiber orientation was noted to affect the response of the materials to UV and moisture environments. For CF/PPS, UV exposure led to enhanced unidirectional tensile and flexure properties, and quasi-isotropic compression strength, but reduced in-plane shear properties of cross-ply laminates and the short-beam shear strength of unidirectional laminates. Exposure to moisture had minimal effect on CF/PPS laminates. UV light caused a slight decrease in tensile strength and strain of unidirectional samples of GF/PPS and a slight increase in these properties with various degrees in quasi-isotropic samples. Exposure to moisture was noted to cause a reduction in most of the mechanical properties with various degrees in unidirectional and quasi-isotropic GF/PPS laminates. For GF/PP, exposure to UV and moisture decreased the tensile and compressive strengths of unidirectional and quasi-isotropic laminates. However, a notable increase in flexure strength was observed in both laminates after UV exposure. The GF/PET quasi-isotropic laminates showed reduced tension, compression, and flexure strengths but increased impact resistance and short-beam strength under UV exposure, while moisture decreased in-plane shear properties of cross-ply laminates and increased the glass transition temperature of unidirectional laminates. Vertical burn and surface flammability and smoke generation tests showed high flame resistance of CF/PPS and GF/PPS composites, and less so for GF/PP and GF/PET composites. The findings highlight the various responses of the materials to extreme environments. Full article

Carbon fiber-reinforced thermoplastic composites (CFRTPs) have attracted increasing attention in aerospace, transportation, marine engineering, and other advanced manufacturing fields owing to their high specific mechanical properties, impact resistance, weldability, reprocessibility, and potential recyclability. However, the high melt viscosity of thermoplastic matrices, the permeability limitations associated with different reinforcement architectures, and the chemical inertness of carbon fiber surfaces continue to restrict resin impregnation, interfacial bonding, defect control, and forming stability. This review systematically summarizes recent advances in CFRTP manufacturing from the perspective of material-derived processing challenges and interface engineering. First, representative thermoplastic matrix systems and reinforcement architectures are discussed, with emphasis on their effects on processability, crystallization behavior, resin flow, and load transfer. Subsequently, six major forming processes, including hot stamping, injection molding, pultrusion, filament winding, automated fiber placement, and additive manufacturing, are critically compared in terms of processing principles, typical defects, technical limitations, and application boundaries. Particular attention is given to process-induced quality issues such as voids, wrinkling, springback, fiber breakage, warpage, insufficient consolidation, and weak interlayer bonding. Finally, interface engineering strategies, including chemical surface modification, interfacial structural design, and functional interlayer design, are reviewed as practical routes to improve wetting, shorten impregnation pathways, and enhance fiber–matrix load transfer in high-viscosity thermoplastic systems. This review highlights that CFRTP manufacturing should be understood as a coupled materials–processing–interface problem rather than a single forming operation. Future development is discussed with emphasis on reproducible manufacturing, processability-oriented materials, scalable interface engineering, predictive modeling, and standardized structural validation. Full article

Battery housings are critical structural and safety components in electric vehicles, fulfilling multiple functions related to mechanical protection, crashworthiness, thermal management, fire resistance, electromagnetic shielding, and integration of battery modules into the vehicle body. While metallic housings, particularly aluminum and steel, remain dominant in industrial applications, increasing attention is being given to composite materials as lightweight alternatives capable of improving energy efficiency and extending driving range. However, the growing use of composites in battery enclosures raises important questions regarding recyclability, end-of-life management, and compatibility with circular economy principles. This review critically examines the current state of the art in composite materials used for electric vehicle battery housings, with particular emphasis on glass- and carbon-fiber-reinforced thermoplastics, thermoset composites, sandwich structures, and hybrid multi-material systems. The paper discusses the functional requirements imposed on battery housings and analyzes how these requirements influence material selection and design strategies. Particular attention is devoted to recycling pathways applicable to composite battery enclosures, including mechanical recycling, thermal treatment, chemical recycling, and reuse-oriented approaches, as well as to the limitations associated with mixed-material assemblies, adhesives, coatings, and integrated functions. The review also addresses circular design strategies for battery housings, including design for disassembly, material traceability, modularity, and the incorporation of recycled polymers and secondary reinforcements into new housing systems. Current research gaps are identified in the integration of structural performance, fire safety, manufacturability, and recyclability within a single design framework. The analysis shows that thermoplastic composites currently offer the most promising route toward circular battery enclosures, while thermoset-based systems still face significant challenges in high-value recycling. The paper concludes by outlining future research directions required for the development of lightweight, safe and recyclable composite battery housings aligned with sustainable mobility and circular economy goals. Full article

The curing quality of epoxy resin at wind turbine blade joint seams critically affects blade integrity and service reliability, yet conventional metallic heating systems often suffer from poor temperature uniformity, limited flexibility, and slow thermal response. In this study, a flexible and lightweight heating blanket based on carbon nanotube (CNT) electrothermal film was developed for blade reinforcement and in situ curing applications. The device employs a multilayer composite architecture consisting of a CNT heating layer, a nano-aerogel thermal insulation layer, a thermoplastic polyurethane electrical insulation layer, and a silicone-coated glass fiber protective layer, together with an intelligent temperature control system. The resulting blanket, with a total thickness of 3.85 mm, exhibited rapid and stable heating performance, increasing from 25 to 120 °C within 8 min. Under resin-curing conditions, it achieved an initial heating rate of 7.2 °C min⁻¹ and a temperature uniformity of ±2.6 °C, markedly outperforming a conventional Ni@Cr alloy heating blanket. Accelerated aging tests further demonstrated stable electrothermal performance under the tested condition. Those results indicate that the proposed CNT-based heating blanket provides an efficient and reliable thermal management strategy for large curved composite structures. Full article

Fused deposition modeling (FDM) provides a flexible manufacturing route for continuous fiber-reinforced thermoplastic composites, but weak interlaminar bonding and the trade-off between load-bearing capacity and deformation capability still limit their structural applications. In this study, multi-scale carbon/Kevlar fiber hybridization was introduced into acrylonitrile butadiene styrene (ABS)-based composites by combining continuous carbon fiber (CCF) or continuous Kevlar fiber (CKF) with short carbon fiber-filled ABS (ABS/SCF) or short Kevlar fiber-filled ABS (ABS/SKF). Four hybrid configurations and two continuous-fiber baseline composites were fabricated by FDM and evaluated through three-point bending tests, floating roller peel tests, peeled-surface SEM observations, and Rule-of-Mixtures-based hybrid effect analysis. The flexural results showed that short-fiber-filled matrices improved the flexural properties of both CCF- and CKF-based composites, but the degree of improvement depended on the fiber combination. Among the investigated configurations, CCF + ABS/SCF exhibited the highest flexural modulus and strength, which were 34.31% and 27.26% higher than those of CCF + ABS, respectively. For the CKF-based composites, CKF + ABS/SCF increased the flexural modulus and strength by 31.51% and 26.78%, compared with CKF + ABS, while maintaining the progressive deformation behavior associated with Kevlar reinforcement. The peel results showed that all hybrid composites had higher interlaminar peel resistance than their corresponding baselines, with increases ranging from 18.66% to 54.42%. The peeled-surface SEM observations indicated that the short-fiber-filled matrices changed the crack-propagation features, with more matrix tearing, fiber pull-out, and irregular peeling areas. The RoM-based comparison showed that the measured flexural properties of all hybrid configurations were higher than the corresponding RoM reference values. Overall, CCF + ABS/SCF was more suitable for improving stiffness and load-bearing capacity, whereas CKF + ABS/SCF showed a more balanced response in terms of flexural performance, interlaminar peel resistance, and progressive deformation behavior. Full article

The rapid growth in the use of carbon fiber-reinforced polymers (CFRPs) and fused-deposition-modeled (FDM) polylactic acid (PLA) has generated substantial non-biodegradable and thermoplastic waste streams, creating urgent needs for scalable recycling and valorization strategies. This study develops and evaluates an integrated route that chemically recovers carbon fibers (CFs) from CFRP waste and converts them into high-performance reinforcements for recycled PLA matrices. CFRP fragments were pre-swollen in acetic acid (120 °C, 1 h), then depolymerized by means of oxidation with 1 M KMnO₄ (100 °C, 2 h), washed, dried (100 °C, 24 h), and size-reduced by means of cryogenic milling. Recycled CFs (treated) and untreated CFRP fragments were blended with 3D-printing PLA waste at 10, 20 and 30 wt.% via melt mixing (175 °C, 5 min, 70 rpm) and molded into ASTM D638 dog-bone specimens. Materials were characterized via XRD, FTIR, Raman, SEM and mechanical testing. XRD and Raman confirmed retention of the graphitic backbone after treatment; FTIR and Raman revealed oxygen-containing surface functionalization consistent with oxidation, while SEM showed effective removal of epoxy and improved fiber surface cleanliness. Compared with neat PLA (tensile strength 45.4 MPa; modulus 2.6 GPa; elongation 6.3%), composites reinforced with chemically recycled CFs exhibited marked mechanical enhancement: at 30 wt.% treated CF, the tensile strength increased to 102.6 MPa (+126%), elastic modulus to 11.7 GPa (+350%), and toughness to 250.3 MPa, while ductility decreased to 2.9%. Equivalent composites with untreated CFRP exhibited smaller gains (30 wt.%: tensile 87.3 MPa; modulus 10.3 GPa), highlighting the benefit of epoxy removal and surface activation for fiber–matrix adhesion. The proposed chemical recycling pathway is operationally simple and cost-effective, produces reusable CFs with preserved graphitic structure and enhanced surface chemistry, and enables the fabrication of high-performance, waste-derived PLA composites suitable for structural and engineering applications. This work demonstrates a viable waste-to-value approach that advances circularity for both CFRP and 3D-printing polymer waste streams. Full article

Thermoplastic fiber metal laminates (TFMLs) are lightweight hybrid materials combining metallic layers with fiber-reinforced thermoplastic composites, offering a high strength-to-weight ratio. Existing studies indicate a limited range of polymer matrices used in such structures, most commonly polyamide 6 (PA6). In this work, polybutylene terephthalate (PBT) was selected as a potential alternative matrix because literature data indicate its lower moisture absorption and good dimensional stability compared with PA6. A comparative analysis of TFMLs based on aluminum and carbon fabric-reinforced composites with PA6 and PBT matrices was conducted. Static tensile tests were performed on base materials, composites, and laminates, supported by analytical modeling using the superposition method and fractographic analysis. The results showed that fiber orientation and polymer content significantly affect stiffness, strength, and damage evolution. Fiber orientation remains the governing factor, controlling load transfer and damage initiation. Laminates with 0/90° fibers exhibited the highest strength, while ±45° configurations showed reduced performance due to shear-dominated deformation. The polymer primarily acts as a matrix, ensuring structural integrity, with comparable mechanical properties for both systems. Delamination at the metal–composite interface was identified as the dominant failure mechanism. Full article

Short carbon fiber-reinforced thermoplastic composites (SCFRTPCs) are widely employed in energy, aerospace and competitive sports due to their high specific strength/stiffness and design freedom. The Large Format Additive Manufacturing (LFAM) process, as an advanced technology for fabricating thermoplastic composite components, enables the rapid production of complex large-scale composite components and prototypes. Nevertheless, achieving satisfactory mechanical load-bearing performance remains a key challenge. To overcome this limitation, a methodology was developed for manufacturing short carbon fiber/Nylon 6 (SCF/PA6) composite components with programmable load-bearing performance via large-format additive manufacturing–compression molding (LFAM-CM). This process innovatively synergizes material stiffness enhancement with component deposition path planning, utilizing the high-orientation and low-porosity tape-shaped beads produced by LFAM to fabricate components. The experimental results demonstrate a peak load capacity of 549N, representing 33%, 231%, and 144% enhancements versus randomly oriented fiber, high-porosity, and non-path-planned components, respectively. Simultaneous meso- and macro-scale bearing performance analysis demonstrated the cross-scale synergistic enhancement effect of this process on component load-bearing capacity. Finally, a systematic analysis of energy dissipation, stiffness, and damage tolerance revealed the underlying mechanisms for enhanced load-bearing performance. This work establishes an expanded design paradigm where multivariate coupling replaces linear structure–property relationships, providing practical frameworks for the development of next-generation functionally graded components with tailored mechanical–electrical–thermal multifunctionality. Full article

Processing parameters play a key role in the mechanical, thermo-mechanical and creep-recovery properties of unidirectional carbon fiber reinforced thermoplastic polypropylene (CF/PP) composites because of high matrix viscosity, which governs their impregnation and interfacial bonding. This study systematically investigates the effects of molding temperature (190~210 °C), pressure (1~3 MPa), and holding time (5~15 min) on its short beam strength (SBS), storage modulus, loss modulus, tan δ, creep strain, strain recovery, and crystallinity using a Taguchi experimental design. The results presented that processing parameters have a huge effect on CF/PP composites’ SBS, and through the experimental design, the SBS could be improved by 68.1% (21.3~35.8 MPa). Holding time is the most influential parameter for SBS and damping performance, while temperature and pressure interact strongly, highlighting the importance of parameter synergy. There was a strong negative correlation between the crystallinity degree and the SBS of CF/PP composites, and a higher crystallinity degree means a sharper and higher melting peak. Creep-recovery tests reveal near-complete recovery (87~102%) at 30 °C, which decreases to 71~79% at 80 °C due to increased matrix mobility. Finally, it was confirmed that the relatively low SBS of CF/PP composites comes from the void and incomplete matrix impregnation of fibers. The above results advance the design of high-performance, sustainable thermoplastic composites for civil and structural engineering applications. Full article

Hydrogen transport under high-pressure conditions poses significant challenges for pipeline materials and structural design. Existing studies on PA12-based systems are primarily limited to material-level characterization, with insufficient validation at the pipeline scale. To address this gap, this study presents the design and system-level experimental validation of an all-thermoplastic composite hydrogen pipeline. A full-scale DN50 pipeline, consisting of a PA12 liner and a ±54° filament-wound carbon fiber-reinforced layer, was fabricated and tested under hydrogen pressures up to 10 MPa, including long-term exposure and cyclic loading. The results indicate stable deformation behavior and low hydrogen permeation (~10⁻¹⁴ mol·m/(m²·s·Pa)) within the investigated pressure range, with a burst pressure exceeding 60 MPa. A transition from stable to accelerated deformation was identified at elevated pressure, indicating a structural operating limit. Post-test observations reveal that interlaminar damage, rather than primary interface failure, governs long-term degradation. Based on these findings, a design framework integrating stress-based, deformation-based, and damage-based criteria is proposed. This work extends PA12-based hydrogen pipeline research from material-level understanding to system-level validation and provides practical guidance for structural design and performance evaluation. Full article

Carbon fiber-reinforced thermoplastic composite drilling is a secondary manufacturing process because the quality of drilled holes affects assembly system performance, structure, and sustainability. This paper compares all drill coating types and cutting conditions for PEEK-CF30 composite drilling utilizing a hybrid experimental–statistical method. DLC-, TiN-, and TiCN-coated HSS drills, as well as cutting speed and feed rate were tested using the Taguchi L27 design. Performance indicators were measured by including thrust force, surface roughness, drilling torque, and energy consumption. Experimental results showed that increasing cutting speed and feed rate increased the thrust force while decreasing torque and energy consumption. Smearing on the hole surface, chip adhesion, and short fiber adhesion/pull were identified as indicators of poor surface quality, and these occurrences increased with increasing drill coating removal at high cutting parameters. In terms of overall performance, the TiCN-coated drill created the lowest thrust force (50.85 N), surface roughness (1.038 µm), torque (17.54 Ncm), and energy consumption (136.45 J) at high feed conditions. Taguchi-based gray relational analysis methodology revealed that the TiCN-coated drill, a cutting speed of 40 m/min, and a feed rate of 0.1 mm/rev are the optimum parameters. Second-order prediction models developed for all responses proved to have high predictive capabilities with coefficients of determination above 94%. Ultimately, drill coating quality considerably affected surface integrity and drilling energy consumption performance in drilling PEEK-CF30. A hybrid optimization and modeling framework demonstrates that the drill quality cutting parameter will allow for optimum selection to ensure efficient processing of advanced thermoplastic composites. Full article

Thermoplastic composite resistance welding boasts stable process, low cost and reliable quality, making it a dependable joining technique for such materials. This process employs a heating element (HE) as the sole heat source and therefore, it is critical in controlling the welding process. This study proposed a perforated stainless-steel mesh (SSM) as the HE and investigated the effect of welding parameters and insulation film thickness on the joint performance of resistance welded carbon-fiber-reinforced polyamide 6 (CF/PA6). The results showed that the joint lap shear strength (LSS) increased first then decreased as the welding pressure, welding time and welding current increased. The maximum LSS reached 24.4 MPa when 0.2-mm-thick films were used. The joint failure mode was identified as blocky fiber peeling with compromised fiber continuity for the joints welded with 0.1-mm-thick and 0.3 mm-thick PA6 films. For the joints made with 0.2-mm-thick PA6 films, the joint failure mode was characterized by resin peeling from the fiber surface. Full article

Continuous unidirectional (UD) thermoplastic composite tapes are increasingly used in aerospace, automotive, and energy applications because of their high specific strength, low weight, recyclability, and compatibility with automated manufacturing. Since final component performance strongly depends on tape quality, reliable defect characterization and detection are essential. In this study, manufacturing-induced defects in polypropylene-based UD tapes reinforced with carbon and glass fibers were investigated using real images acquired directly from laboratory-scale production without synthetic data. Defects related to interfacial integrity, matrix distribution, fiber architecture, and surface irregularities were systematically analyzed, and a practical four-class defect taxonomy was established. To enable automated inspection under limited-data conditions, lightweight YOLOv8, YOLOv11, and the new YOLO26 models were comparatively evaluated using a UD tape-specific augmentation strategy combining physically constrained Albumentations and on-the-fly augmentation. Among the tested models, YOLO26-s achieved the best overall performance, reaching a mean mAP@0.5 of 0.87 ± 0.03, outperforming YOLOv11 (0.83) and YOLOv8 (0.78), with 0.90 precision and 0.85 recall. Interfacial (0.92 mAP) and matrix-related (0.90 mAP) defects were detected most reliably, whereas fiber-related (0.89 mAP) and surface defects (0.79 mAP) remained more challenging, particularly in glass-fiber-reinforced tapes due to transparency-masking effects. The results demonstrate the potential of compact deep learning models for computationally efficient and manufacturing-relevant in-line quality monitoring of UD tape production. Full article

Carbon fiber-reinforced thermoplastic (CFRTP) composites are now widely used in many fields. Ultrasonic welding (UW) is a key technology for joining these materials. The control mode of UW has a great effect on the quality of the welded joints. However, there is still not enough research comparing the different welding control modes. This paper investigates the effects of the time control, energy control, and displacement control modes on the ultrasonic welding quality of carbon fiber-reinforced polycarbonate (CF/PC). A flat PC film is used as the energy director (ED). The evaluation focuses on the lap-shear strength (LSS), macro- and micro-morphology, fracture surface characteristics and power–displacement curves of the welding process. Furthermore, significant differences are observed in the temperature field evolution and joint failure modes across the different control modes and process parameters. Results indicate that the displacement control mode achieves the highest joint quality and process stability, yielding a maximum LSS of 30.6 MPa. A correlation analysis reveals that the displacement–energy relationship exhibits the strongest coupling, and the Pearson correlation coefficient r is 0.896. Full article