Towards Sustainable Composite Manufacturing with Recycled Carbon Fiber Reinforced Thermoplastic Composites.

Currently, the vast majority of composite waste is either landfilled or incinerated, causing a massive burden on the environment and resulting in the loss of potentially valuable raw material. Here, conventional pyrolysis and reactive pyrolysis were used to reclaim carbon fibers from aeronautical scrap material, and to evaluate the feasibility of using reclaimed carbon fibers in structural components for the automotive sector. The need for fiber sizing was investigated as well as the behavior of the fiber material in macroscopic impact testing. The fibers were characterized with the single fiber tensile test, scanning electron microscopy, and the microbond test. Critical fiber length was estimated in both polypropylene and polyamide matrices. Tensile strength of the fiber material was better preserved with the reactive pyrolysis compared to the conventional pyrolysis, but in both cases the interfacial shear strength was retained or even improved. The impact testing revealed that the components made of these fibers fulfilled all required deformation limits set for the components with virgin fibers. These results indicate that recycled carbon fibers can be a viable option even in structural components, resulting in lower production costs and greener composites.

Cut-off Scale and Complex Formation in Density Functional Theory Computations of Epoxy-Amine Reactivity.

Most of the properties of epoxy resins are tied to their degree of cross-linking, making understanding the reactivity of different epoxy systems a crucial aspect of their utilization. Here, epoxy-amine reactivity is studied with density functional theory (DFT) at various cut-off levels to explore the suitability of the method for estimating the reactivity of specific epoxy systems. Although it is common to use minimal structures in DFT to reduce computational cost, the results of this study highlight the important role of hydrogen bonding and other noncovalent interactions in the reactivity. This is a promising result for differentiating the most probable reactive paths for different resin systems. The significance of amine groups as a potential source of catalyzing H-bonds was also explored and, while not quite as effective as a catalyst as a hydroxyl group, a clear catalyzing effect was observed in the transition state energies. Unfortunately, the added complexity of a more representative reactive system also results in increased computational cost, highlighting the need for proper selection of structural cutoffs.

Microscale sensor solution for data collection from fibre-matrix interfaces.

Especially the applications of fibrous composites in miniature products, dental and other medical applications require accurate data of microscale mechanics. The characterization of adhesion between single filament and picoliter-scale polymer matrix usually relies on the experiments using so-called microbond (MB) testing. The traditional MB test systems provide unitary data output (i.e., converted force) which is enigmatic in resolving the fracture parameters of multi-mode interface cracks. As a fundamental basis, the momentary reaction force and respective local strain at the location of a non-ambiguous gradient are needed for a mechanical analysis. In this paper, a monolithic compliant based structure with an integrated Fiber Bragg Grating (FBG) sensor is developed and analysed. The stiffness of the compliant structure is estimated by using mathematical and finite element (FE) models. Qualification experiments are carried out to confirm the functional performance: MB testing of synthetic (carbon and glass) and natural (flax) single filaments are successfully performed. Quasi-static and dynamic analysis of the MB testing is carried out by using the FE method to interpret the response of the compliant structure. The developed strain-sensing CBPM-FBG holder shows excellent sensitivity during the MB tests for both synthetic and natural filaments, even at a low filament diameters as low as [Formula: see text], making the monolithic compliant structure the first instrument capable of force-strain data output for bonded filament-droplet specimens.

Resizing Approach to Increase the Viability of Recycled Fibre-Reinforced Composites.

Most recycling methods remove the essential sizing from reinforcing fibres, and many studies indicate the importance of applying sizing on recycled fibres, a process we will denote here as resizing. Recycled fibres are not continuous, which dissociates their sizing and composite lay-up processes from virgin fibres. In this study, commercial polypropylene and polyurethane-based sizing formulations with an aminosilane coupling agent were used to resize recycled glass and carbon fibres. The impact of sizing concentration and batch process variables on the tensile properties of fibre-reinforced polypropylene and polyamide composites were investigated. Resized fibres were characterized with thermal analysis, infrared spectroscopy and electron microscopy, and the tensile properties of the composites were analysed to confirm the achievable level of performance. For glass fibres, an optimal mass fraction of sizing on the fibres was found, as an excess amount of film former has a plasticising effect. For recycled carbon fibres, the sizing had little effect on the mechanical properties but led to significant improvement of handling and post-processing properties. A comparison between experimental results and theoretical prediction using the Halpin-Tsai model showed up to 81% reinforcing efficiency for glass fibres and up to 74% for carbon fibres.