AB081. Experience using CFR-PEEK implants in metastatic and primary spine tumour surgery: a single centre retrospective study.

BACKGROUND: Titanium has been the conventional implant material of choice for fixation in both primary and metastatic spine tumour surgeries (MSTS). However, these implants result in artefact generation during post-operative computed tomography (CT) or magnetic resonance imaging (MRI), resulting in poor planning of radiotherapy (RT) and suboptimal tumour surveillance. Carbon fibre-reinforced polyetheretherketone (CFR-PEEK) implants have gained momentum for instrumentation in MSTS due to their radiolucent properties. This in turn does not sacrifice the biomechanical strength of the implants. In this study, we compared the peri-operative outcomes, post operative imaging artefacts and dosimetricdata of CFR-PEEK implants to titanium implants to asses for potential benefits in post-operative RT planning in patients who underwent MSTS. METHODS: This is a retrospective study involving 42 patients operated for MSTS. Patient-related data including demographics, tumour pathology, intra-operative data, functional outcome, and RT-related data were collected for both groups. All patients were followed-up post-operatively for a minimum of 2 years or until demise, whichever was earlier. RESULTS: In our study, 20 (47.6%) patients had CFR-PEEK implants, while 22 (52.4%) of patients had titanium implants used for MSTS. Both groups of patients had similar clinical outcomes for pain and overall survival predictability pre-operatively (P>0.05). Mean number of levels instrumented by titanium screws were 6.8±2.93, while for the CFR-PEEK screws were 4.07±1.05. Mean volume of artefact generated during post operative CT was 75.1±43.4 mm3 in titanium group and 13.3±14.2 mm3 in CFR-PEEK group (P=0.005). The mean time taken to contour the artefacts was 17.3±5.84 minutes in the titanium group, while the CFR-PEEK group took 9.60±7.17 minutes (P=0.049). CONCLUSIONS: Our study suggests that carbon fibre reinforced PEEK screws significantly reduce artefact generation and the time taken to contour them during post-operative RT planning, while delivering equivalent clinical and functional outcomes as compared to standard titanium implants.

Design, manufacturing and experimental validation of additive manufacturing cores for bearing seats in carbon fibre reinforced polymer structures.

The integration of carbon-fibre reinforced polymers (CFRP) in structural applications offers significant advantages due to their high strength-to-weight ratio. However, these materials exhibit limitations under out-of-plane loads, particularly in bearing applications. This study explores an innovative approach to enhance the performance of CFRP structures in such scenarios by incorporating annular polyamide inserts manufactured via additive manufacturing (AM). To evaluate the mechanical performance of the AM inserts, a novel ring tensile test is designed to emulate the bearing load conditions. This test also enables the analysis of the impact of several design and manufacturing parameters of the AM inserts, including surface geometry, surface treatment, internal structure, and curing process. These are then compared with specimens made of carbon fibre sheet moulding compounds (CF-SMC), commonly used to support bearing loads. The study reveals that AM inserts provide a viable alternative to state-of-the-art CF-SMC, offering a significant enhancement in mechanical properties under specific bearing loading conditions. The test results indicate a 17.7% improvement in the first failure limit and an 8.6% increase in the ultimate strength for AM inserts compared to CF-SMC. Additionally, the study develops a simplified analytical model to predict stress distributions and potential failure mechanisms, validating its efficacy through experimental data with discrepancies of less than 6%. Economic analysis underscores the cost benefits of AM inserts due to reduced labour and higher repeatability. This research demonstrates the potential of AM inserts to improve the stability and strength of CFRP structures, paving the way for their broader application in demanding load-bearing environments.

Development and Manufacturing of a Fibre Reinforced Thermoplastic Composite Spar Produced by Oven Vacuum Bagging.

The limited recyclability of fibre-reinforced thermoset composites has fostered the development of alternative thermoplastic-based composites and their manufacturing processes. The most common thermoplastic-based composites are often costly due to their availability in the form of prepreg materials and to the high pressure and temperatures required for their manufacturing. Yet, the manufacturing of economic and recyclable composites, made of semi-preg composite materials using traditional composite manufacturing technologies, has only been proved at a laboratory scale through the manufacturing of flat plates. This work reports the manufacturing of a real structural part, a wing spar section with complex geometry, made of commingled polyamide 12 (PA12) fibres and carbon fibres (CFs) semi-preg and by oven vacuum bagging (OVB). The composite layup was studied using finite element analysis, and processing simulation assisted in the determination of the PA12/CF preform for OVB. Processing of two forms of semi-preg materials was first evaluated and optimised. The material selection for part manufacturing was mainly defined by the materials' processability. The spar section was manufactured in two OVB stages and was then mechanically tested. The mechanical test showed a linear strain response of the prototype up to the maximum load and validated the optimised layup configuration of the composite structure.

Structural Positive Electrodes Engineered for Multifunctionality.

Multifunctional structural batteries are of high and emerging interest in a wide variety of high-strength and lightweight applications. Structural batteries typically use pristine carbon fiber as the negative electrode, functionalized carbon fiber as the positive electrode, and a mechanically robust lithium-ion transporting electrolyte. However, electrochemical cycling of carbon fibre-based positive electrodes is still limited to tests in liquid electrolytes, which does not allow for to introduction of multifunctionality in real terms. To overcome these limitations, structural batteries with a structural battery electrolyte (SBE) are developed. This approach offers massless energy storage. The electrodes are manufactured using economically friendly, abundant, cheap, and non-toxic iron-based materials like olivine LiFePO4. Reduced graphene oxide, renowned for its high surface area and electrical conductivity, is incorporated to enhance the ion transport mechanism. Furthermore, a vacuum-infused solid-liquid electrolyte is cured to bolster the mechanical strength of the carbon fibers and provide a medium for lithium-ion migration. Electrophoretic deposition is selected as a green process to manufacture the structural positive electrodes with homogeneous mass loading. A specific capacity of 112 mAh g-1 can be reached at C/20, allowing the smooth transport of Li-ion in the presence of SBE. The modulus of positive electrodes exceeded 80 GPa. Structural battery-positive half-cells are demonstrated across various mass-loadings, enabling them to be tailored for a diverse array of applications in consumer technology, electric vehicles, and aerospace sectors.

Bond Shear Tests to Evaluate Different CFRP Shear Strengthening Strategies for I-Shaped Concrete Cross-Sections.

I-shaped concrete girders are widely used in precast bridge and roof construction, making them a common structural component in existing infrastructure. Despite well-established strengthening techniques using various innovative materials, such as externally bonded carbon fibre reinforced polymer (CFRP) reinforcement, the shear strengthening of an I-shaped concrete girder is not straightforward. Several research studies have shown that externally bonded CFRP reinforcement might exhibit early debonding at the concave corners of the I-shape, resulting in a marginal increase in shear capacity. This research study aims to assess the performance of two different CFRP shear strengthening strategies for I-shaped concrete cross-sections. In the first strategy, CFRP was bonded along the I-shape of the cross-section with the provision of additional anchorage. In the second strategy, the I-shape was transformed into a rectangular shape by using in-fill blocks over which the CFRP was bonded in a U-configuration. In addition to the strengthening strategies, the investigated parameters included two different materials for the in-fill blocks (conventional and aerated concrete) and two different anchoring schemes (bolted steel plate anchor and CFRP spike anchor). To avoid testing on large-scale girders, a new test methodology has been implemented on concrete I-sections. The test results demonstrate the feasibility of comparing different shear strengthening configurations dedicated to I-sections. Among other findings, the results showed that the local transformation of the I-shape to an equivalent rectangular shape could be a viable solution, resulting in shear strength enhancement of 12% to 53% without and with the anchorages, respectively.

Capacitive Sensors Based on Recycled Carbon Fibre (rCF) Composites.

Recycled carbon fibre (rCF) composites are increasingly being explored for applications such as strain sensing, manufacturing of automobile parts, assistive technologies, and structural health monitoring due to their properties and economic and environmental benefits. The high conductivity of carbon and its wide application for sensing makes rCF very attractive for integrating sensing into passive structures. In this paper, capacitive sensors have been fabricated using rCF composites of varying compositions. First, we investigated the suitability of recycled carbon fibre polymer composites for different sensing applications. As a proof of concept, we fabricated five touch/proximity sensors and three soil moisture sensors, using recycled carbon fibre composites and their performances compared. The soil moisture sensors were realised using rCF as electrodes. This makes them corrosion-resistant and more environmental-friendly, compared to conventional soil moisture sensors realised using metallic electrodes. The results of the touch/proximity sensing show an average change in capacitance (ΔC/C~34) for 20 mm and (ΔC/C~5) for 100 mm, distances of a hand from the active sensing region. The results of the soil moisture sensors show a stable and repeatable response, with a high sensitivity of ~116 pF/mL of water in the linear region. These results demonstrate their respective potential for touch/proximity sensing, as well as smart and sustainable agriculture.

Comparative Evaluation of Fracture Resistance of Carbon Fiber Posts and Glass Fiber Posts in Permanent Anterior Teeth: An In Vitro Study.

Introduction Dental caries and traumatic injuries often lead to tooth loss in adolescents and adults, necessitating endodontic treatment and subsequent restoration. Restoring such teeth presents a challenge due to varying degrees of substance loss. After endodontic treatment, the choice of an appropriate post is crucial for long-term stability. While metal posts are sturdy, they lack aesthetics and may cause root fractures. Fiber posts, such as carbon and glass fiber, offer improved aesthetics and mechanical properties, but their comparative performance warrants investigation. Materials and methods A total of 30 extracted anterior single-rooted teeth were divided into two groups to receive either carbon fiber or glass fiber posts. After endodontic treatment and post-space preparation, the posts were cemented using a dual polymerizing adhesive resin composite. Fracture resistance was assessed using a universal testing machine. Results The mean fracture resistance of the carbon fiber post group was recorded at 271.2 N, whereas the glass fiber post group exhibited a significantly higher mean fracture resistance of 416.133 N. This difference in fracture resistance between the two groups was found to be statistically significant (p < 0.05). Conclusion Glass fiber post systems demonstrated superior fracture resistance compared to carbon fiber post systems in anterior single-rooted teeth. These findings support the clinical preference for glass fiber posts in restoring endodontically treated anterior teeth, offering both mechanical reliability and aesthetic advantages. However, further research, including long-term clinical trials, is warranted to validate these findings and assess the overall clinical performance and longevity of fiber post systems in real-world settings.

Optimising Recycling Processes for Polyimine-Based Vitrimer Carbon Fibre-Reinforced Composites: A Comparative Study on Reinforcement Recovery and Material Properties.

We investigated the recycling process of carbon fibre-reinforced polyimine vitrimer composites and compared composites made from virgin and recycled fibres. The vitrimer matrix consisted of a two-component polyimine-type vitrimer system, and as reinforcing materials, we used nonwoven felt and unidirectional carbon fibre. Various diethylenetriamine (DETA) and xylene solvent ratios were examined to find the optimal dissolution conditions. The 20:80 DETA-xylene ratio provided efficient dissolution, and the elevated temperature (80 °C) significantly accelerated the process. Scaling up to larger composite structures was demonstrated. Scanning electron microscopy (SEM) confirmed effective matrix removal, with minimal residue on carbon fibre surfaces and good adhesion in recycled composites. The recycled nonwoven composite exhibited a decreased glass transition temperature due to the residual solvents in the matrix, while the UD composite showed a slight increase. Dynamic mechanical analysis on the recycled composite showed an increased storage modulus for nonwoven composites at room temperature and greater resistance to deformation at elevated temperatures for the UD composites. Interlaminar shear tests indicated slightly reduced adhesion strength in the reprocessed composites. Overall, this study demonstrates the feasibility of recycling vitrimer composites, emphasising the need for further optimisation to ensure environmental and economic sustainability while mitigating residual solvent and matrix effects.

Mechanical recycling of CFRPs based on thermoplastic acrylic resin with the addition of carbon nanotubes.

Carbon fibre-reinforced polymers (CFRPs) are commonly used in aviation, automotive and renewable energy markets, which are constantly growing. Increasing the production of composite parts leads to increased waste production and a future increase in end-of-life components. To improve the recyclability of CFRPs, new materials that fit in with the idea of a circular economy should be used as a composite matrix. One such material is a commercially available thermoplastic liquid resin, Elium® (Arkema, France). In this work, the authors investigated how the mechanical recycling process affects the properties of thermoplastic-based carbon fibre composites. CFRPs with neat Elium® resin and resin modified with 0.02 wt.% single-walled carbon nanotubes or 0.02 wt.% multi-walled carbon nanotubes were manufactured using the resin infusion process. Afterwards, prepared laminates were mechanically ground, and a new set of composites was manufactured by thermopressing. The microstructure, mechanical, thermal and electrical properties were investigated for both sets of composites. The results showed that mechanical grinding and thermopressing processes lead to a significant increase in the electrical conductivity of composites. Additionally, a sharp decrease in all mechanical properties was observed.

Unsupervised machine learning for flaw detection in automated ultrasonic testing of carbon fibre reinforced plastic composites.

The use of Carbon Fibre Reinforced Plastic (CFRP) composite materials for critical components has significantly surged within the energy and aerospace industry. With this rapid increase in deployment, reliable post-manufacturing Non-Destructive Evaluation (NDE) is critical for verifying the mechanical integrity of manufactured components. To this end, an automated Ultrasonic Testing (UT) NDE process delivered by an industrial manipulator was developed, greatly increasing the measurement speed, repeatability, and locational precision, while increasing the throughput of data generated by the selected NDE modality. Data interpretation of UT signals presents a current bottleneck, as it is still predominantly performed manually in industrial settings. To reduce the interpretation time and minimise human error, this paper presents a two-stage automated NDE evaluation pipeline consisting of a) an intelligent gating process and b) an autoencoder (AE) defect detector. Both stages are based on an unsupervised method, leveraging density-based spatial clustering of applications with noise clustering method for robust automated gating and undefective UT data for the training of the AE architecture. The AE network trained on ultrasonic B-scan data was tested for performance on a set of reference CFRP samples with embedded and manufactured defects. The developed model is rapid during inference, processing over 2000 ultrasonic B-scans in 1.26 s with the area under the receiver operating characteristic curve of 0.922 in simple and 0.879 in complex geometry samples. The benefits and shortcomings of the presented methods are discussed, and uncertainties associated with the reported results are evaluated.

Recycling potential of carbon fibres in the construction industry: From a technical and ecological perspective.

Even though carbon fibres (CFs) have been increasingly used, their end-of-life (EOL) handling presents a challenge. To address this issue, we evaluated the use of recycled CFs (rCFs), produced through pyrolysis, as rovings to be used in textile reinforced concrete structures. Mechanical processing (hammer mill) with varying machine settings was then used to assess EOL handling, considering the separation potential of rCFs and the length of separated rCFs. The results showed that rCF rovings can be separated from concrete with an average of 87 wt.-%, whereas the highest rCF length and separation yield were observed in different machine settings. In addition, a techno-environmental assessment on the mechanical process was performed to compare different machine settings. The machine settings with the highest yield of rCF rovings also had the highest fine fraction that cannot be further separated. Furthermore, life cycle assessment (LCA) was conducted covering three life cycles of CFs and an additional LCA for comparing rCF with virgin CF. LCA results revealed that CF reinforced plastic and concrete productions are the two main contributors to environmental impacts. The comparative LCA between virgin CF and rCF also showed that using rCF is environmentally advantageous, as virgin CF production causes 230% more global warming potential compared to rCF. Future studies assessing different allocation approaches, quantifying the quality of rCF, and its inclusion in LCA are relevant.

Valorisation of Sub-Products from Pyrolysis of Carbon Fibre-Reinforced Plastic Waste: Catalytic Recovery of Chemicals from Liquid and Gas Phases.

Waste carbon fibre-reinforced plastics were recycled by pyrolysis followed by a thermo-catalytic treatment in order to achieve both fibre and resin recovery. The conventional pyrolysis of this waste produced unusable gas and hazardous liquid streams, which made necessary the treatment of the pyrolysis vapours. In this work, the vapours generated from pyrolysis were valorised thermochemically. The thermal treatment of the pyrolysis vapours was performed at 700 °C, 800 °C and 900 °C, and the catalytic treatment was tested at 700 °C and 800 °C with two Ni-based catalysts, one commercial and one homemade over a non-conventional olivine support. The catalysts were deeply characterised, and both had low surface area (99 m2/g and 4 m2/g, respectively) with low metal dispersion. The thermal treatment of the pyrolysis vapours at 900 °C produced high gas quantity (6.8 wt%) and quality (95.5 vol% syngas) along with lower liquid quantity (13.3 wt%) and low hazardous liquid (92.1 area% water). The Ni-olivine catalyst at the lowest temperature, 700 °C, allowed us to obtain good gas results (100% syngas), but the liquid was not as good (only 58.4 area% was water). On the other hand, the Ni commercial catalyst at 800 °C improved both the gas and liquid phases, producing 6.4 wt% of gas with 93 vol% of syngas and 13.6 wt% of liquid phase with a 97.5 area% of water. The main reaction mechanisms observed in the treatment of pyrolysis vapours were cracking, dry and wet reforming and the Boudouard reaction.

The Influence of Flame Exposure and Solid Particle Erosion on Tensile Strength of CFRP Substrate with Manufactured Protective Coating.

This paper presents the results of laboratory tests for new materials made of a carbon fibre-reinforced polymer (CFRP) composite with a single-sided protective coating. The protective coatings were made of five different powders-Al2O3, aluminium, quartz sand, crystalline silica and copper-laminated in a single process during curing of the prepreg substrate with an epoxy matrix. The specimens were subjected to flame exposure and solid particle erosion tests, followed by uniaxial tensile tests. A digital image correlation (DIC) system was used to observe the damage location and deformation of the specimens. All coatings subjected to solid particle erosion allowed an increase in tensile failure force ranging from 5% to 31% compared to reference specimens made of purely CFRP. When exposed to flame, only three of the five materials tested, Al2O3, aluminium, quartz sand, could be used to protect the surface, which allowed an increase in tensile failure force of 5.6%.

Fabrication and failure characteristics of asymmetric balsa-core based fibre composite sandwich beams under 3-point bending test.

The failure characteristics of an asymmetric balsa-core based fibre composite sandwich beam subjected to 3-point bending are investigated analytically and experimentally. The experimental specimens comprise a balsa wood core and two types of fibre composite skins, notably glass fibre and carbon fibre. During the static bending test, the effects of carbon fibre loading (CL) face and glass fibre loading (GL) face on bending failure behaviour are tested. Since the skin thickness, span lengths, and core thicknesses has substantial effect on the structural failures. Therefore, a detailed analysis has been carried out considering the effect of varying span lengths, skin thicknesses, and core thicknesses on several failure modes, particularly indentation, face yield, and core-shear. For the analysis, fourteen specimens have been fabricated, each with a specific geometry and face loading conditions. This report consists of a detailed fabrication flow and loading conditions. Finally, the work has been benchmarked with already published report on asymmetric sandwich structures. The analysis's predictions and the results of the experiment indicate remarkable concordance.

Mouldable Conductive Plastic with Optimised Mechanical Properties.

This paper investigates making an injection mouldable conductive plastic formulation that aims for conductivity into the electromagnetic interference (EMI) shielding range, with good mechanical properties (i.e., stiffness, strength, and impact resistance). While conductivity in the range (electrostatic charge dissipation) and EMI shielding have been attained by incorporating conductive fillers such as carbon black, metals powders, and new materials, such as carbon nanotubes (CNTs), this often occurs with a drop in tensile strength, elongation-to-break resistance, and impact resistance. It is most often the case that the incorporation of high modulus fillers leads to an increase in modulus but a drop in strength and impact resistance. In this work, we have used short carbon fibres as the conductive filler and selected a 50/50 PBT/rPET (recycled PET) for the plastic matrix. Carbon fibres are cheaper than CNTs and graphenes. The PBT/rPET has low melt viscosity and crystallises sufficiently fast during injection moulding. To improve impact resistance, a styrene-ethylene-butadiene-styrene (SEBS) rubber toughening agent was added to the plastic. The PBT/rPET had very low-impact resistance and the SEBS provided rubber toughening to it; however, the rubber caused a drop in the tensile modulus and strength. The short carbon fibre restored the modulus and strength, which reached higher value than the PBT/rPET while providing the conductivity. Scanning electron microscope pictures showed quite good bonding of the current filler (CF) to the PBT/rPET. An injection mouldable conductive plastic with high conductivity and raised modulus, strength, and impact resistance could be made.

Mechanical Strength and Surface Analysis of a Composite Made from Recycled Carbon Fibre Obtained via the Pyrolysis Process for Reuse in the Manufacture of New Composites.

This work aims to obtain recycled carbon fibre and develop an application for this new material. The carbon fibres were obtained by recycling aerospace prepreg waste via the pyrolysis process. The recycled fibres were combined with an Araldite LH5052/Aradur LY5053 epoxy resin/hardener system using manual lay-up and vacuum bagging processes. For comparison, the same resin/hardener system was used to produce a composite using commercial carbon fibre. The recycled and commercial composites were subjected to flexural, tensile and Mode I testing. Fracture aspects were analysed via scanning electron microscopy (SEM). The pyrolysis process did not affect the fibre surface as no degradation was observed. The fracture aspect showed a mixture of failure in the recycled composite laminate and interlaminar/translaminar failure near the surface of the commercial composite caused by flexural stress. Flexural and tensile tests showed a loss of mechanical strength due to the recycling process, but the tensile values were twice as high. The sand ladder platform was the project chosen for the development of a product made with recycled carbon fibres. The product was manufactured using the same manufacturing process as the specimens and tested with a 1243 kg car. The method chosen to design, manufacture and test the prototype sand ladder platform made of recycled carbon fibre was appropriate and gave satisfactory results in terms of high mechanical strength to bending and ease of use.

Construction of a stable S-scheme NiSnO3/g-C3N4 heterojunction on activated carbon fibre for the degradation of glyphosate in water under flow condition.

Creating light-harvesting heterojunctions as a photocatalyst is critical for efficiently treating organics-laden wastewater. Yet the materials stabilization and limited reusability hinder their practical applications. In this study, an S-scheme heterojunction in the Sn-based perovskite and g-C3N4 (gCN) composite, supported on an activated carbon fiber (ACF) substrate, is developed for glyphosate (GLP) degradation under water under flow conditions. The reusable NiSnO3-gCN/ACF photocatalyst was synthesized using a simple wet impregnation and calcination method. The supported photocatalyst achieved 99% GLP-removal at 4 mL/min water flowrate and 1.25 g/m2 of photocatalyst loading in ACF. The photocatalyst showed a stable structure and repeat photocatalytic performance across 5 cycles despite prolonged visible light exposure under flow conditions. The materials stability is attributed to the effective dispersion of NiSnO3-gC3N4 in ACF, preventing the photocatalyst from elution in water flow. Radical trapping experiment revealed the superoxide and hydroxyl radicals as the primary reactive species in the GLP-degradation pathway. A plausible S-scheme mechanism was proposed for heterojunction formation, based on the high resolution deconvoluted spectra of X-ray photoelectron spectroscopy and the radical trapping experimental results. The inexpensive Sn-based perovskite synthesized in this study is indicated as an alternative to Ti-based perovskites for wastewater remediation application.

Simulation-Based Identification of Operating Point Range for a Novel Laser-Sintering Machine for Additive Manufacturing of Continuous Carbon-Fibre-Reinforced Polymer Parts.

Additive manufacturing using continuous carbon-fibre-reinforced polymer (CCFRP) presents an opportunity to create high-strength parts suitable for aerospace, engineering, and other industries. Continuous fibres reinforce the load-bearing path, enhancing the mechanical properties of these parts. However, the existing additive manufacturing processes for CCFRP parts have numerous disadvantages. Resin- and extrusion-based processes require time-consuming and costly post-processing to remove the support structures, severely restricting the design flexibility. Additionally, the production of small batches demands considerable effort. In contrast, laser sintering has emerged as a promising alternative in industry. It enables the creation of robust parts without needing support structures, offering efficiency and cost-effectiveness in producing single units or small batches. Utilising an innovative laser-sintering machine equipped with automated continuous fibre integration, this study aims to merge the benefits of laser-sintering technology with the advantages of continuous fibres. The paper provides an outline, using a finite element model in COMSOL Multiphysics, for simulating and identifying an optimised operating point range for the automated integration of continuous fibres. The results demonstrate a remarkable reduction in processing time of 233% for the fibre integration and a reduction of 56% for the width and 44% for the depth of the heat-affected zone compared to the initial setup.

Numerical Simulations of Carbon-Fibre Impregnation with a Polymer as an Anisotropic Permeability Medium.

The impregnation process of carbon fibres with polymers is challenging to model due to the system's complexity, particularly concerning the following aspects: the complex rheology of the polymeric matrices and the presence of solid, continuous fibres, both with anisotropic properties, and the interaction between solid and fluid, which can change the displacement of fibres into a cyclic dependence. In this work, an interesting approach was considered by setting the fibres as a porous medium whose properties were calculated with microscale/macroscale cycle modelling. In the microscale modelling stage, two main assumptions can be made: (i) a homogeneous distribution with a representative cell or (ii) a stochastic distribution of fibres. The solution to the abovementioned flow and fibre distribution problem can severely differ with only a slight change in a single parameter for a given set of processing parameters. Therefore, the influence of some of them during the fibre impregnation process was evaluated, allowing a shortcut for the polymer through a gap between fibres and the bottom wall of the extrusion die. The range of investigated values regarding the gap enables one to cover good impregnation conditions up to the occurrence of the shortcut and consequent poor impregnation quality. These studies were performed with numerical simulations with circa 126,000 degrees of freedom, considering the discretisation mesh elements and the unknowns (pressure and two velocity components).

Finite Element Simulation and Experimental Assessment of Laser Cutting Unidirectional CFRP at Cutting Angles of 45° and 90°.

Laser cutting of carbon fibre-reinforced plastics (CFRP) is a promising alternative to traditional manufacturing methods due to its non-contact nature and high automation potential. To establish the process for an industrial application, it is necessary to predict the temperature fields arising as a result of the laser energy input. Elevated temperatures during the cutting process can lead to damage in the composite's matrix material, resulting in local changes in the structural properties and reduced material strength. To address this, a three-dimensional finite element model is developed to predict the temporal and spatial temperature evolution during laser cutting. Experimental values are compared with simulated temperatures, and the cutting kerf geometry is examined. Experiments are conducted at 45° and 90° cutting angles relative to the main fibre orientation using a 1.1 mm thick epoxy-based laminate. The simulation accurately captures the overall temperature field expansion caused by multiple laser beam passes over the workpiece. The influence of fibre orientation is evident, with deviations in specific temperature data indicating differences between the estimated and real material properties. The model tends to overestimate the ablation rate in the kerf geometry, attributed to mesh resolution limitations. Within the parameters investigated, hardly any expansion of a heat affected zone (HAZ) is visible, which is confirmed by the simulation results.