Search Results (59)

The IDEA project, developed in the frame of MOST—National Centre for Sustainable Mobility—addressed the growing need for reliable bonded joints in fibre-reinforced polymer composite structures used in transportation. Purely bonded joints are preferred for their lightweight and cost-efficient properties, but contamination and defect detection issues often make them unreliable. To solve this, the project developed innovative surface treatments, a methodology for the safe, optimized design of bonded joints, and structural health monitoring solutions, viable for real-time assessment. These advancements aim to increase the reliability and safety of bonded connections, helping industries adopt lighter, purely bonded joints over heavier, hybrid bonded/bolted options. Full article

This article is a numerical and experimental study of the mechanical properties of different glass, flax and hybrid composites. By utilizing hybrid composites consisting of natural fibers, the aim is to eventually reduce the percentage usage of synthetic or man-made fibers in composites and obtain similar levels of mechanical properties that are offered by composites using synthetic fibers. This in turn would lead to greener composites being utilized. The advantage of which would be the presence of similar mechanical properties as those of composites made from synthetic fibers along with a reduction in the overall weight of components, leading to much more eco-friendly vehicles. Finite element simulations (FEM) of mechanical properties were performed using ANSYS. The FEM simulations and analysis were performed using standards as required. Subsequently, actual beams/frames with a defined geometry were fabricated for applications in automotive body construction. The tensile performance of such frames was also simulated using ANSYS-based models and was experimentally verified. A correlation with the results of the FEM simulations of mechanical properties was established. The maximum tensile strength of 415 MPa was found for sample 1: G-E (glass–epoxy composite) and the minimum strength of 146 MPa was found for sample 2: F-G-E (G-4) (flax–glass–epoxy composite). The trends were similar, as obtained by simulation using ANSYS. A comparison of the results showed the accuracy of the numerical simulation and experimental specimens with a maximum error of about 8.05%. The experimental study of the tensile properties of polymer matrix composites was supplemented with interlaminar shear strength, and a high accuracy was found. Further, the maximum interlaminar shear strength (ILSS) of 18.5 MPa was observed for sample 1: G-E and the minimum ILSS of 17.0 MPa was observed for sample 2: F-G-E (G-4). The internal fractures were analyzed using a computer tomography analyzer (CTAn). Sample 2: F-G-E (G-4) showed significant interlaminar cracking, while sample 1: G-E showed fiber failure through the cross section rather than interlaminar failure. The results indicate a practical solution of a polymer composite frame as a replacement for existing heavier components in a car, thus helping towards weight reduction and fuel efficiency. Full article

A comprehensive modeling framework for the thermoforming of polymer matrix woven laminate composite was developed. Two numerical indicators, the slip path length and traction magnitude, have been identified to be positively correlated to matrix smearing and wrinkling defects. The material model has been calibrated with picture-frame experimental results, and the prediction accuracy for intra-ply shear and thickness distribution was examined with measurements of the physically formed parts. Specifically, thickness prediction for most locations on the formed parts was accurate within an 11.6% error margin. However, at two points with significant intra-ply shear, the prediction errors increased to around 20%. Finally, a parametric study was conducted to determine the relationship between various process parameters and the quality of the formed part. For the trapezoidal part, orienting the laminate at 45 degrees to the mold axis reduces the likelihood of matrix smear and wrinkling defects. Although this laminate orientation yielded a greater spatial variation in part thickness, the thickness deviation is lower than that for the 0-degree orientation case. Two forming analyses were conducted with ramp rates of 25 mm/s and 80 mm/s to match the equipment’s operational limits. It was observed that higher forming rates led to a greater likelihood of defects, as evidenced by a 15% and 10% increase in the formed part areas with longer slip paths and higher traction magnitudes, respectively. It was discovered that shallower molds benefit from faster ramp rates, while deeper molds require slower rates to manage extensive shearing, stretching and bending. Faster forming rates lead to smaller thickness increases at high intra-ply shear regions, indicating a shift from intra-ply shear to out-of-plane bending due to the visco-plastic effect of the molten laminate and can negatively impact part quality. Lastly, it was shown that a well-conceived strategy using darts could improve the part quality by reducing the magnitude of the defect indicators. Full article

The paper presents a review of End-of-Life scenarios (EoL) (disposal, incineration, chemical, thermal and mechanical recycling) compared to the production stage of Fibre-Reinforced Polymers (FRPs) of composites regarding global warming potential. Innovative FRP manufacturing technologies (vacuum infusion, ultraviolet curved pultrusion, hot stamping, three-dimensional printing and automatic tape placement) commonly used in the shipbuilding industry were environmentally assessed. The materials, energy flows and waste discharged to the environment over the whole life cycle were collected, identified and quantified based on Life Cycle Assessment (LCA) analysis in the frame of the Fibre4Yards project. The results of LCA calculations show that waste management (the EoL scenario) contributes 5 to 39% of the total carbon footprint for FRP technologies. The highest contribution of the EoL scenario was found for technologies where polypropylene was applied, i.e., 33 and 38% of the total CO₂ emissions. Our analysis of the literature and information from industrial partners confirm that the standard and most common waste scenario for FRP materials and compounds is still incineration and landfilling. Full article

As the construction industry places increasing emphasis on environmental conservation and sustainability, this trend has spurred profound research into the optimization of door and window performance. One of the critical components of windows is their frames. Over the past several decades, the design of window frames has undergone significant innovations, ranging from introducing new materials to novel design concepts. The performance of window frames is typically influenced by materials, structural design, and the surrounding environment. Consequently, this paper analyzes the common window frame materials in Chinese civil buildings through investigation. It explores commonly used types of window frames available in the market, focusing on their materials and structural designs. It analyzes issues observed during their usage, integrates findings from existing research, and discusses the performance of window frame materials. Additionally, it explores improvement strategies to meet the evolving demands of contemporary and future architectural doors and windows, providing valuable reference points for designers. Finally, approaching the discussion from a sustainable development perspective, the paper evaluates the environmental impact of wood, aluminum alloy, polymer, and composite window frame materials. It emphasizes that wood- and aluminum-clad wood windows represent sustainable options with versatile applications in diverse scenarios. Full article

Hydrogen is a dangerous gas as it reacts very easily with oxygen and may explode; therefore, the accumulation of hydrogen in confined spaces is a safety hazard. Composites consisting of unsaturated polymers and catalysts are a common getter, where the commonly used polymer is 1,4- diphenylethynyl benzene (DEB). Silicone rubber (SR) is a good carrier for hydrogen-absorbing materials due to its excellent chemical stability and gas permeability. In this work, polysiloxane, water, and a emulsifier are ultrasonically injected into a uniform emulsion, and the hydrogen getter DEB-Pd/C (Palladium on carbon) is then added. Under the catalysis of platinum (Pt), the cross-linking agent undergoes a hydrosilylation reaction to cross-link polysiloxane in emulsion to form silicone rubber. Then, the water was removed by freeze-drying, and the loss of water constructed a porous frame structure for silicone rubber, thus obtaining porous silicone rubber. The difference in hydrogen absorption performance between porous silicone rubber and ordinary silicone rubber was compared. It was found that, with the increase in water in the emulsion, the porous frame of silicone rubber was gradually improved, and the hydrogen absorption performance was improved by 243.4% at the highest, almost reaching the theoretical saturated hydrogen absorption capacity. Porous silicone rubber was prepared by emulsion mixing, which provided a new idea for further improving the hydrogen absorption performance of silicone rubber. Full article

Using fiber-reinforced polymer composite to replace metal in window frames has become a trend in aircraft manufacturing to achieve structural weight reduction. This study proposes an innovative winding compression molding process for continuous production of aircraft window frames using continuous carbon fiber-reinforced polyamide 6 thermoplastic composite filaments (CF/PA6). Through process parameter optimization, the production cycle of CF/PA6 composite window frames was controlled within 5 min, with an ultra-low porosity of 0.69%, meeting aviation application standards. Combining mechanical property experimental tests and finite element analysis, the mechanical performance of window frames made from three different materials was compared and evaluated. In the hoop direction, the mechanical performance of the continuous CF/PA6 thermoplastic window frames were significantly higher than that of chopped CF/epoxy compression molding window frames and aluminum alloy window frames. In the radial direction, the maximum strain occurred at the corner with the highest curvature of the frame due to the absence of fiber reinforcement, resulting in weak pure interlayer shear. Nevertheless, the thermoplastic CF/PA6 winding compression molded window frame still exhibited a high resistance to crack propagation and damage, as evidenced by the absence of any detectable sound of microdamage during testing with a 9000 N load. It is believed that achieving a further-balanced design of hoop–radial performance by appropriately introducing radial ply reinforcement can lead to a significant weight reduction goal in the window frame. The findings in this study provide an innovative process reference that can be universally applicable to high-speed and near-net-shape manufacturing without material waste of continuous fiber-reinforced thermoplastic composite products. Full article

Life cycle assessment (LCA) is used to evaluate the environmental load of fibre composite manufacturing technologies in the shipyards industry in a frame of the Fibre4Yards (Horizon 2020) project. This paper is focused on the LCA of fibre-reinforced polymer (FRP) technologies used to produce all elements of the floating unit, i.e., the conventional vacuum infusion technology for the deck panel and adaptive mould process for superstructure panels, ultraviolet (UV) curved pultrusion process for the production of stiffeners, hot stamping technology for brackets, and three-dimensional (3D) printing and automatic tape placement (ATP) for pillars. Environmental impact was assessed based on standard indicators: Global Warming Potential, water consumption, and fossil resource scarcity. The results indicate that the total carbon footprint of analysed FRP technologies is mainly produced by the type of the materials applied rather than by the amount of energy consumed during the process. Full article

As the construction industry moves toward sustainable building practices, incorporating wood-based materials into building envelope systems has become a priority. This paper investigates the environmental impact of three custom bio-composite Façade System Modules (FSMs) through an Embodied Carbon Assessment (ECA), focused on the Global Warming Potential indicator of life cycle stages from cradle to practical completion (A1–A5). The evaluated FSMs were developed within the Basajaun H2020 project (G.A. 862942), by substituting and combining conventional materials with other bio-composite products to form hybrids from bio-based polymers and wood. A benchmark ECA was conducted, simulating alternative FSMs devised with common practice solutions for the curtain wall façade to facilitate a comprehensive comparison. The life cycle inventory encompassed detailed technical information, fostering the utilization of primary data for accuracy. The study particularly highlights considerations over three technological systems of the modules that incorporate increased use of wood-based components and a novel bio-composite material: the frame profiles, the insulation equipment, and the seal system. Despite the challenges due to the Basajaun FSMs’ weight, the findings reveal that replacing the currently used materials with wood-based materials and bio-composites reduced the embodied emissions, particularly substituting aluminum frame profiles. The insights presented here offer indicators toward circular, environmentally conscious, bio-composed building envelopes, emphasizing the need for continued analysis and refinements as a consequence of increasing the accuracy of the available primary data from the supply chain and concerning end-of-life scenarios. Full article

Using a wheelchair over uneven terrain generates vibrations of the human body. These vibrations result from mechanical energy impulses transferred from the ground through the wheelchair components to the user’s body, which may negatively affect the quality of the wheelchair use and the user’s health. This energy can be dissipated through the structure of the wheelchair frame, such as polymer and carbon fiber composites. This article aims to compare a wheelchair with an aluminum alloy frame and a carbon fiber frame in terms of reducing kinematic excitation acting on the user’s body. Three wheelchairs were used in the study, one with an aluminum alloy frame (reference) and two innovative ones with composite frames. The user was sitting in the tested wheelchairs and had an accelerometer attached to their forehead. The vibrations were generated by applying impulses to the rear wheels of the wheelchair. The obtained results were analyzed and compared, especially regarding differences in the damping decrement. The research shows that using modern materials in the wheelchair frame has a beneficial effect on vibration damping. Although the frame structure and material did not significantly impact the reduction in the acceleration vector, the material and geometry had a beneficial effect on the short dissipation time of the mechanical energy generated by the kinematic excitation. Research has shown that modern construction materials, especially carbon fiber-reinforced composites, may be an alternative to traditional wheelchair suspension modules, effectively damping vibrations. Full article

With increasing interest in the rapid development of lattice structures, hybrid additive manufacturing (HAM) technology has become a competent alternative to traditional solutions such as water jet cutting and investment casting. Herein, a HAM technology that combines vat photopolymerization (VPP) and electroless/electroplating processes is developed for the fabrication of multifunctional polymer-metal lattice composites. A VPP 3D printing process is used to deliver complex lattice frameworks, and afterward, electroless plating is employed to deposit a thin layer of nickel-phosphorus (Ni-P) conductive seed layer. With the subsequent electroplating process, the thickness of the copper layer can reach 40 μm within 1 h and the resistivity is around $1.9\times {10}^{-8} \mathsf{\Omega }\cdot \mathrm{m}$, which is quite close to pure copper ($1.7 \times {10}^{-8} \mathsf{\Omega }\cdot \mathrm{m}$). The thick metal shell can largely enhance the mechanical performance of lattice structures, including structural strength, ductility, and stiffness, and meanwhile provide current supply capability for electrical applications. With this technology, the frame arms of unmanned aerial vehicles (UAV) are developed to demonstrate the application potential of this HAM technology for fabricating multifunctional polymer-metal lattice composites. Full article

Composite booms for solar sails have been prototyped by using innovative smart materials. Shape memory polymer composites (SMPCs) have been manufactured by interposing SMP layers between carbon-fiber-reinforced (CFR) plies. A polyimide membrane has been embedded into the CFR-SMPC frame of the sail during lamination. The sail’s size has been limited to 250 × 250 mm² to allow its testing on Earth. The feasibility of large sail deployments has been shown by prototyping small CFR-SMPC elements to insert only in the folding zones. Numerical simulation by finite element modeling allowed for predicting the presence of wrinkles close to the frame’s vertexes in the cases of large sails under solar radiation pressures. Nevertheless, the frame’s configuration, with SMPC booms at all the edges of the sail membrane, seems to be suitable for drag sails instead of propulsion. On-Earth recovery tests have been performed on 180° folded sails by using flexible heaters. After an initial induction time, the maximum rate was reached with a following drop. In the case of two heaters per folding zone, the angular recovery rate reached the maximum value of about 30 deg/s at the power of 34 W, and full recovery was made in 20 s. Full article

Enhancing mechanical properties of environmentally friendly and renewable polymers by the introduction of natural fibers not only paves the way for developing sustainable composites but also enables new opportunities in advanced additive manufacturing (AM). In this paper, wood fibers, as a versatile renewable resource of cellulose, are integrated within bio-based polylactic acid (PLA) polymer for the development and 3D printing of sustainable and recycle green composites using fused deposition modeling (FDM) technology. The 3D-printed composites are comprehensively characterized to understand critical materials properties, including density, porosity, microstructures, tensile modulus, and ultimate strength. Non-contact digital image correlation (DIC) technology is employed to understand local stress and strain concentration during mechanical testing. The validated FDB-based AM process is employed to print honeycombs, woven bowls, and frame bins to demonstrate the manufacturing capability. The performance of 3D-printed honeycombs is tested under compressive loads with DIC to fully evaluate the mechanical performance and failure mechanism of ultra-light honeycomb structures. The research outcomes can be used to guide the design and optimization of AM-processed composite structures in a broad range of engineering applications. Full article

Automated fiber placement (AFP) is a method to manufacture complex composite parts in an automatable and scalable process. Thermoplastic in situ AFP has received more attention in recent years for its use in high-performance, aerospace applications that use low-melting polyaryletherketone (LM-PAEK) composites. Although in situ AFP is a promising technology for the automated and economical manufacturing of composites, the production of a mold is still a considerable expense. Using large-scale additive manufacturing, molds can be manufactured in a short time frame for a fraction of the cost of traditional molds. By using polyamide 6 (PA6), a polymer incompatible with LM-PAEK, a bond can be created, which holds a laminate in the desired form during production and allows for demolding. Due to the thermoplastic nature of PA6, a mold can be manufactured using large-scale, extrusion-based additive manufacturing. This study investigates the suitability of 3D-printed molds composed of PA6 for the AFP of CF/LM-PAEK laminates. To this end, peel tests and shear tests were conducted to investigate the influence of the process temperature, the area of heating and the consolidation pressure on the bond of these incompatible polymers. A shear strength of up to 2.83 MPa and a peel strength of up to 0.173 N·mm⁻¹ were achievable. The principal suitability of PA6 as a mold material for the AFP of CF/LM-PAEK was demonstrated. Full article

Frames made of polymer composites are increasingly used in the aerospace, automotive, and agricultural industries. A frequently used technology in the production line of composite frames is winding rovings onto a non-load-bearing frame to form the structure using an industrial robot and a winding head, which is solidified through a subsequent heat-treatment pressure process. In this technology, the most difficult procedure is the winding of the curved parts of a composite frame. The primary concern is to ensure the proper winding angles, minimize the gaps and overlaps, and ensure the homogeneity of the wound layers. In practice, the curved frame parts very often geometrically form sections of a torus. In this work, the difficulty of achieving a uniform winding of toroidal parts is described and quantified. It is shown that attaining the required winding quality depends significantly on the geometrical parameters of the torus in question. A mathematical model with a detailed procedure describing how to determine the number of rovings of a given width on toroidal parts is presented. The results of this work are illustrated with practical examples of today’s industrial problems. Full article