Pub Date : 2025-09-10DOI: 10.1016/j.jcomc.2025.100644
Junro Sano, Ryosuke Matsuzaki
To overcome the limitations of conventional continuous carbon fiber 3D printing in achieving precise curved printing and intricate shaping, a 3D printing technique based on carbon nanotube (CNT) yarn was proposed, offering finer and more accurate fabrication capabilities. However, the contributions of two critical features of CNT yarn—its fine diameter and yarn twist—to enhanced printability remain inadequately understood. This study explores the impact of these features on printing precision through a combination of experimental methods and machine learning approaches. The findings reveal that yarn twist plays a more significant role than diameter in reducing radius errors during single-layer circular printing. A predictive model developed in this study achieved an value of 0.888 and reduced radius error magnitude by approximately 79.3% when feedback was incorporated into the printing process. These results highlight the potential of CNT yarn to advance the precision of 3D printing technologies.
{"title":"Improving the accuracy of carbon nanotube yarn 3D printing using machine learning","authors":"Junro Sano, Ryosuke Matsuzaki","doi":"10.1016/j.jcomc.2025.100644","DOIUrl":"10.1016/j.jcomc.2025.100644","url":null,"abstract":"<div><div>To overcome the limitations of conventional continuous carbon fiber 3D printing in achieving precise curved printing and intricate shaping, a 3D printing technique based on carbon nanotube (CNT) yarn was proposed, offering finer and more accurate fabrication capabilities. However, the contributions of two critical features of CNT yarn—its fine diameter and yarn twist—to enhanced printability remain inadequately understood. This study explores the impact of these features on printing precision through a combination of experimental methods and machine learning approaches. The findings reveal that yarn twist plays a more significant role than diameter in reducing radius errors during single-layer circular printing. A predictive model developed in this study achieved an <span><math><msup><mrow><mi>R</mi></mrow><mrow><mn>2</mn></mrow></msup></math></span> value of 0.888 and reduced radius error magnitude by approximately 79.3% when feedback was incorporated into the printing process. These results highlight the potential of CNT yarn to advance the precision of 3D printing technologies.</div></div>","PeriodicalId":34525,"journal":{"name":"Composites Part C Open Access","volume":"18 ","pages":"Article 100644"},"PeriodicalIF":7.0,"publicationDate":"2025-09-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145044679","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Interfacial adhesion is a pivotal factor in determining the overall strength and durability of composite structures across aerospace and automotive industries. Therefore, understanding the failure modes and crack propagation paths in interface-based composites underpins the service life of bulk structure. This study employs deep learning and information fusion techniques to automate structure-property analysis in adhesive joints. First, response surface methodology (RSM) is used to design experimental matrix for anodizing adherend surfaces (aluminium sheets); the control parameters are concentration, current and time. Surface topography is characterized by surface roughness and contact angle along with scanning electron microscopy (SEM) images. Interfacial strength of anodized aluminium-polyurethane (Al-PU) adhesive joints is measured, and fracture analysis is performed via SEM. Experimental results demonstrated that anodizing conditions – concentration 0.5 M H2SO4 concentration, 1.5 A current and 45 min anodizing duration– enhanced the interfacial shear strength by up to 920% compared to untreated joints. Second, a novel information fusion approach is employed; the model integrates features extracted from SEM images using ResNet with numerical data from the RSM’s matrix. The combined representation is fed into an XGBoost model which enables robust material property analysis and regression. Feature-importance analysis via XGBoost and Integrated Gradients provide valuable insights into how anodizing parameters and surface features affect joint strength. Through the combination of numerical data (anodizing conditions and surface topographical features) and surface and fracture image analysis, the model significantly reduced the mean absolute percentage error from 18.8% to 10.7%. The findings highlight the pivotal role of integrating quantitative and qualitative information of structural materials to develop a robust and an accurate machine learning model.
{"title":"Deep learning and information fusion for structure property analysis in adhesive joints","authors":"Umut Bakhbergen , Ahmed Maged , Fethi Abbassi , Reza Montazami , Sherif Araby","doi":"10.1016/j.jcomc.2025.100645","DOIUrl":"10.1016/j.jcomc.2025.100645","url":null,"abstract":"<div><div>Interfacial adhesion is a pivotal factor in determining the overall strength and durability of composite structures across aerospace and automotive industries. Therefore, understanding the failure modes and crack propagation paths in interface-based composites underpins the service life of bulk structure. This study employs deep learning and information fusion techniques to automate structure-property analysis in adhesive joints. First, response surface methodology (RSM) is used to design experimental matrix for anodizing adherend surfaces (aluminium sheets); the control parameters are concentration, current and time. Surface topography is characterized by surface roughness and contact angle along with scanning electron microscopy (SEM) images. Interfacial strength of anodized aluminium-polyurethane (Al-PU) adhesive joints is measured, and fracture analysis is performed <em>via</em> SEM. Experimental results demonstrated that anodizing conditions – concentration 0.5 M H<sub>2</sub>SO<sub>4</sub> concentration, 1.5 A current and 45 min anodizing duration– enhanced the interfacial shear strength by up to 920% compared to untreated joints. Second, a novel information fusion approach is employed; the model integrates features extracted from SEM images using ResNet with numerical data from the RSM’s matrix. The combined representation is fed into an XGBoost model which enables robust material property analysis and regression. Feature-importance analysis <em>via</em> XGBoost and Integrated Gradients provide valuable insights into how anodizing parameters and surface features affect joint strength. Through the combination of numerical data (anodizing conditions and surface topographical features) and surface and fracture image analysis, the model significantly reduced the mean absolute percentage error from 18.8% to 10.7%. The findings highlight the pivotal role of integrating quantitative and qualitative information of structural materials to develop a robust and an accurate machine learning model.</div></div>","PeriodicalId":34525,"journal":{"name":"Composites Part C Open Access","volume":"18 ","pages":"Article 100645"},"PeriodicalIF":7.0,"publicationDate":"2025-09-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145044681","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-08-22DOI: 10.1016/j.jcomc.2025.100642
E. Pirhadi , A.R. Torabi , Sahel Shahbaz , M. Petrů , S.S. R․ Koloor
Characterization of FRP composite laminate subjected to mixed-mode loading is one of the challenging topics in fracture mechanics. In this study, numerous experiments are conducted on U-notched rectangular tension (UNRT) specimens of various tip radii made of E-glass/epoxy composite with various layup configurations for experimental measurement of the translaminar U-notch fracture toughness (TLUNFT) of the composite laminates under mixed mode-I/II loading conditions. Two fracture limit curves are developed based on a two-dimensional stress distribution around the notch for predicting the mixed mode TLUNFT taking advantage of the maximum tangential stress (MTS) and the mean stress (MS) criteria as well as the virtual isotropic material concept (VIMC). It is revealed that both two-dimensional new models, namely the translaminar U-notch maximum tangential stress (TLUN-MTS) and the translaminar U-notch mean stress (TLUN-MS) criteria, can well estimate the experimental results obtained from testing the UNRT specimens made of the unidirectional () and quasi-isotropic () E/glass epoxy composites. It should be underlined that this is the first time that some fracture limit curves have been developed by using the notch fracture mechanics (NFM) for estimating the TLUNFT of laminated composites subjected to mixed mode loading. These curves can be accurately, rapidly, and conveniently utilized to predict the last-ply-failure load of U-notched composite laminates subjected to in-plane loading conditions.
{"title":"Translaminar fracture limit curves for U-notched glass/epoxy composite laminates with different layup configurations subjected to mixed mode- I/II loading","authors":"E. Pirhadi , A.R. Torabi , Sahel Shahbaz , M. Petrů , S.S. R․ Koloor","doi":"10.1016/j.jcomc.2025.100642","DOIUrl":"10.1016/j.jcomc.2025.100642","url":null,"abstract":"<div><div>Characterization of FRP composite laminate subjected to mixed-mode loading is one of the challenging topics in fracture mechanics. In this study, numerous experiments are conducted on U-notched rectangular tension (UNRT) specimens of various tip radii made of E-glass/epoxy composite with various layup configurations for experimental measurement of the translaminar U-notch fracture toughness (TLUNFT) of the composite laminates under mixed mode-I/II loading conditions. Two fracture limit curves are developed based on a two-dimensional stress distribution around the notch for predicting the mixed mode TLUNFT taking advantage of the maximum tangential stress (MTS) and the mean stress (MS) criteria as well as the virtual isotropic material concept (VIMC). It is revealed that both two-dimensional new models, namely the translaminar U-notch maximum tangential stress (TLUN-MTS) and the translaminar U-notch mean stress (TLUN-MS) criteria, can well estimate the experimental results obtained from testing the UNRT specimens made of the unidirectional (<span><math><msub><mrow><mo>[</mo><mn>0</mn><mo>]</mo></mrow><mn>16</mn></msub></math></span>) and quasi-isotropic (<span><math><msub><mrow><mo>[</mo><mrow><mn>0</mn><mo>/</mo><mn>90</mn><mo>/</mo><mo>±</mo><mn>45</mn></mrow><mo>]</mo></mrow><mrow><mn>2</mn><mi>s</mi></mrow></msub></math></span>) E/glass epoxy composites. It should be underlined that this is the <em>first time</em> that some fracture limit curves have been developed by using the notch fracture mechanics (NFM) for estimating the TLUNFT of laminated composites subjected to mixed mode loading. These curves can be accurately, rapidly, and conveniently utilized to predict the last-ply-failure load of U-notched composite laminates subjected to in-plane loading conditions.</div></div>","PeriodicalId":34525,"journal":{"name":"Composites Part C Open Access","volume":"18 ","pages":"Article 100642"},"PeriodicalIF":7.0,"publicationDate":"2025-08-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144921906","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
This study investigates the structural and functional properties of bioglass–iron oxide (Fe₃O₄) composite layers deposited on Ti-6Al-4V substrates via electrophoretic deposition (EPD). Suspensions with varying Fe₃O₄ contents (10, 15, 25, and 50 wt %) were prepared to identify the optimal composition. SEM and elemental mapping revealed that the B90-F10 sample (90 % bioglass, 10 % Fe₃O₄) produced a more uniform and denser coating compared to other compositions, while minimizing porosity and crack formation. The Vickers microhardness of the B90-F10 coating reached 321.3 ± 3.4 HV, higher than that of the pure bioglass coating B100-F0 (295.1 ± 2.3 HV). Surface roughness measurements showed that B90-F10 had a lower average roughness (0.82 ± 0.41 µm) than B100-F0 (2.10 ± 0.46 µm), indicating a smoother, more compact surface. The mean coating thickness for B90-F10 was 148.32 ± 0.02 µm, slightly greater than B100-F0 (140.01 ± 0.01 µm). Contact angle tests confirmed improved hydrophilicity, with B90-F10 showing a reduced contact angle (22.56°) compared to the uncoated substrate (55.16°). Electrochemical tests revealed that although coatings slightly reduced corrosion resistance compared to bare alloy due to residual porosity, the addition of Fe₃O₄ significantly increased charge transfer resistance, indicating better barrier performance than pure bioglass coatings. In vitro bioactivity tests confirmed enhanced formation of hydroxyapatite layers, critical for osseointegration. These findings highlight the coatings’ capacity to augment implant performance by improving mechanical durability, surface characteristics, and bioactivity, thus offering a valuable functional enhancement beyond the untreated substrate.
{"title":"Analysis of the structure and characteristics of bioglass–iron oxide composite layers on Ti-6Al-4V alloy via electrophoretic deposition","authors":"Zahra Sohani, Hamed Jamshidi Aval, Sayed Mahmood Rabiee","doi":"10.1016/j.jcomc.2025.100639","DOIUrl":"10.1016/j.jcomc.2025.100639","url":null,"abstract":"<div><div>This study investigates the structural and functional properties of bioglass–iron oxide (Fe₃O₄) composite layers deposited on Ti-6Al-4V substrates via electrophoretic deposition (EPD). Suspensions with varying Fe₃O₄ contents (10, 15, 25, and 50 wt %) were prepared to identify the optimal composition. SEM and elemental mapping revealed that the B90-F10 sample (90 % bioglass, 10 % Fe₃O₄) produced a more uniform and denser coating compared to other compositions, while minimizing porosity and crack formation. The Vickers microhardness of the B90-F10 coating reached 321.3 ± 3.4 HV, higher than that of the pure bioglass coating B100-F0 (295.1 ± 2.3 HV). Surface roughness measurements showed that B90-F10 had a lower average roughness (0.82 ± 0.41 µm) than B100-F0 (2.10 ± 0.46 µm), indicating a smoother, more compact surface. The mean coating thickness for B90-F10 was 148.32 ± 0.02 µm, slightly greater than B100-F0 (140.01 ± 0.01 µm). Contact angle tests confirmed improved hydrophilicity, with B90-F10 showing a reduced contact angle (22.56°) compared to the uncoated substrate (55.16°). Electrochemical tests revealed that although coatings slightly reduced corrosion resistance compared to bare alloy due to residual porosity, the addition of Fe₃O₄ significantly increased charge transfer resistance, indicating better barrier performance than pure bioglass coatings. In vitro bioactivity tests confirmed enhanced formation of hydroxyapatite layers, critical for osseointegration. These findings highlight the coatings’ capacity to augment implant performance by improving mechanical durability, surface characteristics, and bioactivity, thus offering a valuable functional enhancement beyond the untreated substrate.</div></div>","PeriodicalId":34525,"journal":{"name":"Composites Part C Open Access","volume":"18 ","pages":"Article 100639"},"PeriodicalIF":7.0,"publicationDate":"2025-08-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144887417","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-08-19DOI: 10.1016/j.jcomc.2025.100643
Kay A. Weidenmann , René Alderliesten , Julie J.E. Teuwen
Fiber-metal laminates are a well-known and established material concept featuring an enhanced crack propagation resistance when compared to their metal and fiber reinforced plastic (FRP) constituents. In this paper, this approach is transferred to purely carbon fiber reinforced plastic (CFRP) based laminates made from layers having polyetherimide (PEI) and epoxy matrices in an alternating laminate architecture. The laminates are manufactured via hot pressing. Double-cantilever beam (DCB) tests are performed on standard samples for both the hybrid laminates in different configurations as well for the both constituent materials, i.e. carbon fiber reinforced PEI (CFR-PEI) and carbon fiber reinforced epoxy. As the formation of an interphase is already reported in literature for this matrix combination, microstructural investigations have also been carried out in addition to fractography on crack surfaces. It is shown that the hybrid materials outperform both constituents regarding the crack resistance when crack initiation starts in the tougher CFR-PEI layer and the laminate layup is 0/90°. In the other configurations investigated, there is no significant effect. The energy dissipating mechanisms are crack jumping and the formation of several parallel cracks. Consequently, crack resistance in such hybrids might be controlled in future by adjusting the crack resistance of the constituents as well as the laminate architecture.
{"title":"Thermoset (epoxy) - thermoplastic (polyetherimide) carbon fiber reinforced laminates featuring improved crack resistance in double cantilever beam tests due to hybridization","authors":"Kay A. Weidenmann , René Alderliesten , Julie J.E. Teuwen","doi":"10.1016/j.jcomc.2025.100643","DOIUrl":"10.1016/j.jcomc.2025.100643","url":null,"abstract":"<div><div>Fiber-metal laminates are a well-known and established material concept featuring an enhanced crack propagation resistance when compared to their metal and fiber reinforced plastic (FRP) constituents. In this paper, this approach is transferred to purely carbon fiber reinforced plastic (CFRP) based laminates made from layers having polyetherimide (PEI) and epoxy matrices in an alternating laminate architecture. The laminates are manufactured via hot pressing. Double-cantilever beam (DCB) tests are performed on standard samples for both the hybrid laminates in different configurations as well for the both constituent materials, i.e. carbon fiber reinforced PEI (CFR-PEI) and carbon fiber reinforced epoxy. As the formation of an interphase is already reported in literature for this matrix combination, microstructural investigations have also been carried out in addition to fractography on crack surfaces. It is shown that the hybrid materials outperform both constituents regarding the crack resistance when crack initiation starts in the tougher CFR-PEI layer and the laminate layup is 0/90°. In the other configurations investigated, there is no significant effect. The energy dissipating mechanisms are crack jumping and the formation of several parallel cracks. Consequently, crack resistance in such hybrids might be controlled in future by adjusting the crack resistance of the constituents as well as the laminate architecture.</div></div>","PeriodicalId":34525,"journal":{"name":"Composites Part C Open Access","volume":"18 ","pages":"Article 100643"},"PeriodicalIF":7.0,"publicationDate":"2025-08-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144907113","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-08-19DOI: 10.1016/j.jcomc.2025.100635
Lyazid Bouhala , Jérome Polesel , Argyrios Karatrantos , Séverine Perbal , Björn Senf , Alexander Hiekel , Heiner Reinhardt , Alexander Rauscher , Thomas Mäder
Ensuring the safety and durability of composite pressure vessels is critical due to their extensive use in aerospace, automotive, and energy sectors. This review examines recent advances in Structural Health Monitoring (SHM) technologies tailored for Composite Overwrapped Pressure Vessels (COPVs). Special focus is given to flexible strain sensors based on nanofillers such as carbon nanotubes, graphene, MXene, and polymer nanocomposites, which provide high sensitivity, stretchability, and tunable sensing behavior. Key sensing mechanisms including tunneling, piezo-resistivity, and crack propagation and fabrication methods influencing sensor performance and integration are discussed. Shape memory alloy (SMA) filament sensors are also analyzed for their exceptional fatigue resistance, elastic stretchability, and high gauge factors. Case studies demonstrate their practical effectiveness under cyclic pressure loading and burst tests. The review further highlights multifunctional composites integrating self-sensing features for next-generation smart pressure vessels. Challenges related to sensor embedding, environmental impacts, data processing, and scalability are addressed. Future research directions emphasize multi-scale modeling, machine learning for damage detection and prognosis, and fully autonomous SHM systems enabling real-time safety management. These advances are poised to enhance reliability, reduce maintenance costs, and extend the operational life of composite pressure vessels in demanding industrial applications.
{"title":"Review of State-of-the-art of structural health monitoring in hydrogen composite pressure vessels","authors":"Lyazid Bouhala , Jérome Polesel , Argyrios Karatrantos , Séverine Perbal , Björn Senf , Alexander Hiekel , Heiner Reinhardt , Alexander Rauscher , Thomas Mäder","doi":"10.1016/j.jcomc.2025.100635","DOIUrl":"10.1016/j.jcomc.2025.100635","url":null,"abstract":"<div><div>Ensuring the safety and durability of composite pressure vessels is critical due to their extensive use in aerospace, automotive, and energy sectors. This review examines recent advances in Structural Health Monitoring (SHM) technologies tailored for Composite Overwrapped Pressure Vessels (COPVs). Special focus is given to flexible strain sensors based on nanofillers such as carbon nanotubes, graphene, MXene, and polymer nanocomposites, which provide high sensitivity, stretchability, and tunable sensing behavior. Key sensing mechanisms including tunneling, piezo-resistivity, and crack propagation and fabrication methods influencing sensor performance and integration are discussed. Shape memory alloy (SMA) filament sensors are also analyzed for their exceptional fatigue resistance, elastic stretchability, and high gauge factors. Case studies demonstrate their practical effectiveness under cyclic pressure loading and burst tests. The review further highlights multifunctional composites integrating self-sensing features for next-generation smart pressure vessels. Challenges related to sensor embedding, environmental impacts, data processing, and scalability are addressed. Future research directions emphasize multi-scale modeling, machine learning for damage detection and prognosis, and fully autonomous SHM systems enabling real-time safety management. These advances are poised to enhance reliability, reduce maintenance costs, and extend the operational life of composite pressure vessels in demanding industrial applications.</div></div>","PeriodicalId":34525,"journal":{"name":"Composites Part C Open Access","volume":"18 ","pages":"Article 100635"},"PeriodicalIF":7.0,"publicationDate":"2025-08-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144865504","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-08-19DOI: 10.1016/j.jcomc.2025.100640
Norbert Geier, Gergely Magyar
Machining-induced burr formation in carbon fibre-reinforced polymer (CFRP) composites is difficult to predict and control, mainly due to the anisotropy and inhomogeneity of the fibrous composite, as well as the rapid tool condition change due to the abrasive tool wear. The main aim of this study is to develop a model to determine the density and distribution functions of risky fibre cutting angles where machining-induced burrs are expected to be formed when hole-machining CFRPs. Four models were introduced, and their adequacy was analysed. The coefficients of the models were determined using datasets of three previous research projects (i.e., 2 380 808 data points) and validated through a fourth one (208 571 data points) where hole machining experiments were carried out using different tools, parameters and setups. The normality of the risky fibre cutting angles was tested through the Shapiro-Wilk and Kolmogorov-Smirnov statistical tests, and the distribution was found to be not Gaussian. The developed trigonometric model shows a good fit to the data points, i.e., the determination coefficient is at least 0.949 for each dataset. The results indicate that machining-induced burr formation is most probable at a fibre cutting angle of 118–133°, and 60 % of burr occurrences fall within the 110°–160° range when the critical fibre cutting angle is 133° These findings provide a foundation for the industrial adoption of advanced machining strategies for fibrous polymer composites, enabling a significant reduction of machining‑induced burrs in CFRPs.
{"title":"Machining-induced burr distribution along hole contours in unidirectional carbon fibre-reinforced polymer (UD-CFRP) composites","authors":"Norbert Geier, Gergely Magyar","doi":"10.1016/j.jcomc.2025.100640","DOIUrl":"10.1016/j.jcomc.2025.100640","url":null,"abstract":"<div><div>Machining-induced burr formation in carbon fibre-reinforced polymer (CFRP) composites is difficult to predict and control, mainly due to the anisotropy and inhomogeneity of the fibrous composite, as well as the rapid tool condition change due to the abrasive tool wear. The main aim of this study is to develop a model to determine the density and distribution functions of risky fibre cutting angles where machining-induced burrs are expected to be formed when hole-machining CFRPs. Four models were introduced, and their adequacy was analysed. The coefficients of the models were determined using datasets of three previous research projects (<em>i.e.,</em> 2 380 808 data points) and validated through a fourth one (208 571 data points) where hole machining experiments were carried out using different tools, parameters and setups. The normality of the risky fibre cutting angles was tested through the Shapiro-Wilk and Kolmogorov-Smirnov statistical tests, and the distribution was found to be not Gaussian. The developed trigonometric model shows a good fit to the data points, <em>i.e.,</em> the determination coefficient is at least 0.949 for each dataset. The results indicate that machining-induced burr formation is most probable at a fibre cutting angle of 118–133°, and 60 % of burr occurrences fall within the 110°–160° range when the critical fibre cutting angle is 133° These findings provide a foundation for the industrial adoption of advanced machining strategies for fibrous polymer composites, enabling a significant reduction of machining‑induced burrs in CFRPs.</div></div>","PeriodicalId":34525,"journal":{"name":"Composites Part C Open Access","volume":"18 ","pages":"Article 100640"},"PeriodicalIF":7.0,"publicationDate":"2025-08-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144890188","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-08-13DOI: 10.1016/j.jcomc.2025.100638
Ahmed Ashteyat , Ala T. Obaidat , Tarik Kharabsheh , Ahmed Fayez , Ahmad Al-Khreisat , Mu'tasim Abdel-Jaber
This research investigates the effect of using basalt fiber with different ratios on the impact resistance of heated and unheated two-way slab. Twelve heated and unheated two-way slab specimens of (1.05 m x 1.05 m x 0.07 m) were cast with different basalt fiber ratios of (0.25, 0.50, 0.75, 1.00, and 1.25) % by weight of cement and two fiber lengths of 12 and 24 mm have been exposed to ambient temperature and elevated temperature of (600 °C). This experiment investigates the effect of basalt fiber on the behavior of two-way slab in terms of compressive strength of concrete, punching shear failure, deflection, stiffness, and induced strain. The results showed that adding basalt fibers with different ratios experienced minor improvements in the concrete compressive strength for all specimens. The application of the impact load resulted in the formation of radial and conic cracks originating at the center of the specimen. These cracks indicated that the primary mode of failure is punching shear. Additionally, in this study, it was observed that a gradual increase in the proportion of basalt fibers led to a reduction in both the length and number of cracks. Moreover, for the pattern of the cracks due to static load, it was observed that the development of conical cracks was a result of overloading. The specimen incorporating a 24 mm basalt fiber at a 1 % ratio under unheated conditions demonstrated the significant improvement in performance regarding cracking compared to control. The stiffness and deflection of the specimens were improved by increasing the proportion of basalt fiber. Additionally, employing 24 mm fibers resulted in reduced deflection and increased stiffness compared to using 12 mm fibers.
研究了玄武岩纤维不同配比对加热和未加热双向板抗冲击性能的影响。12个加热和未加热的双向板试件（1.05 m x 1.05 m x 0.07 m）浇铸了不同的玄武岩纤维比（0.25、0.50、0.75、1.00和1.25）%的水泥重量，两种纤维长度分别为12和24 mm，暴露在环境温度和高温（600°C）下。本试验从混凝土抗压强度、冲剪破坏、挠度、刚度和诱导应变等方面考察了玄武岩纤维对双向板性能的影响。结果表明，添加不同比例的玄武岩纤维对各试件的抗压强度均有较小的改善。冲击载荷的作用导致试样中心形成径向裂纹和锥形裂纹。这些裂缝表明，主要破坏方式为冲剪破坏。此外，在本研究中还观察到，随着玄武岩纤维比例的逐渐增加，裂缝的长度和数量都会减少。此外，对于静荷载引起的裂纹模式，观察到锥形裂纹的发展是超载的结果。在不加热的条件下，以1%的比例加入24毫米玄武岩纤维的试样与对照组相比，在开裂方面表现出显著的改善。增加玄武岩纤维的掺量可以改善试件的刚度和挠度。此外，与使用12毫米纤维相比，使用24毫米纤维减少了挠度，增加了刚度。
{"title":"Impact resistance of heated and unheated two-way slab reinforced with basalt fiber","authors":"Ahmed Ashteyat , Ala T. Obaidat , Tarik Kharabsheh , Ahmed Fayez , Ahmad Al-Khreisat , Mu'tasim Abdel-Jaber","doi":"10.1016/j.jcomc.2025.100638","DOIUrl":"10.1016/j.jcomc.2025.100638","url":null,"abstract":"<div><div>This research investigates the effect of using basalt fiber with different ratios on the impact resistance of heated and unheated two-way slab. Twelve heated and unheated two-way slab specimens of (1.05 m x 1.05 m x 0.07 m) were cast with different basalt fiber ratios of (0.25, 0.50, 0.75, 1.00, and 1.25) % by weight of cement and two fiber lengths of 12 and 24 mm have been exposed to ambient temperature and elevated temperature of (600 °C). This experiment investigates the effect of basalt fiber on the behavior of two-way slab in terms of compressive strength of concrete, punching shear failure, deflection, stiffness, and induced strain. The results showed that adding basalt fibers with different ratios experienced minor improvements in the concrete compressive strength for all specimens. The application of the impact load resulted in the formation of radial and conic cracks originating at the center of the specimen. These cracks indicated that the primary mode of failure is punching shear. Additionally, in this study, it was observed that a gradual increase in the proportion of basalt fibers led to a reduction in both the length and number of cracks. Moreover, for the pattern of the cracks due to static load, it was observed that the development of conical cracks was a result of overloading. The specimen incorporating a 24 mm basalt fiber at a 1 % ratio under unheated conditions demonstrated the significant improvement in performance regarding cracking compared to control. The stiffness and deflection of the specimens were improved by increasing the proportion of basalt fiber. Additionally, employing 24 mm fibers resulted in reduced deflection and increased stiffness compared to using 12 mm fibers.</div></div>","PeriodicalId":34525,"journal":{"name":"Composites Part C Open Access","volume":"18 ","pages":"Article 100638"},"PeriodicalIF":7.0,"publicationDate":"2025-08-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144865506","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
To address the restricted application of halogenated flame retardants (FRs), both industrial and academic sectors have endeavored to produce environmentally friendly, effective, and low-toxicity flame retardants for polymers. Bio-based FRs have attracted considerable interest due to their cost-effectiveness, widespread availability, and accessibility. Conversely, nanostructured graphene-based sustainable FRs provide further advantages to polymer composites beyond fire prevention, such as enhanced resistance to degradation, increased thermal stability, mechanical strength and extended lifespan. This review aims to provide a comprehensive summary of the flame retardancy characteristics of polymers and their composites with newly developed bio-based and graphene-based sustainable FRs. The flame-retardant properties, mechanism, and synergistic effects of the recently developed graphene and bio-based (lignin, phytic acid, chitosan, tannic acid, polydopamine, vegetable oil, biocarbon and keratinous fiber) polymer composites are thoroughly discussed in this article. Graphene-based FRs enhance polymer flame resistance by dissipating heat, forming protective barriers, and promoting char formation, reducing heat and gas transfer. Similarly, nitrogen- and phosphorus-rich bio-based FRs improve fire safety by forming dense char layers that block heat and suppress flammable gas release. The superior flame retardancy of these FR-loaded polymer composites allows for their application across various industry sectors, including automotive, aerospace, electronics, military, and construction. However, challenges such as compatibility between the polymer matrix and FRs, expensive and complicated fabrication processes, limitations of raw material supplies and industrial scalability need to be further researched. In conclusion, these FRs offer a promising path toward safer, more effective, per- and polyfluoroalkyl substances (PFAS)-free and more sustainable flame-resistant polymer composites in key industrial sectors.
{"title":"Recent progress in flame retardancy of graphene and bio-based sustainable flame retardants for polymer composite applications","authors":"Suman Kumar Ghosh , Manjusri Misra , Alper Kiziltas , Shawn Prevoir , Amar K. Mohanty","doi":"10.1016/j.jcomc.2025.100637","DOIUrl":"10.1016/j.jcomc.2025.100637","url":null,"abstract":"<div><div>To address the restricted application of halogenated flame retardants (FRs), both industrial and academic sectors have endeavored to produce environmentally friendly, effective, and low-toxicity flame retardants for polymers. Bio-based FRs have attracted considerable interest due to their cost-effectiveness, widespread availability, and accessibility. Conversely, nanostructured graphene-based sustainable FRs provide further advantages to polymer composites beyond fire prevention, such as enhanced resistance to degradation, increased thermal stability, mechanical strength and extended lifespan. This review aims to provide a comprehensive summary of the flame retardancy characteristics of polymers and their composites with newly developed bio-based and graphene-based sustainable FRs. The flame-retardant properties, mechanism, and synergistic effects of the recently developed graphene and bio-based (lignin, phytic acid, chitosan, tannic acid, polydopamine, vegetable oil, biocarbon and keratinous fiber) polymer composites are thoroughly discussed in this article. Graphene-based FRs enhance polymer flame resistance by dissipating heat, forming protective barriers, and promoting char formation, reducing heat and gas transfer. Similarly, nitrogen- and phosphorus-rich bio-based FRs improve fire safety by forming dense char layers that block heat and suppress flammable gas release. The superior flame retardancy of these FR-loaded polymer composites allows for their application across various industry sectors, including automotive, aerospace, electronics, military, and construction. However, challenges such as compatibility between the polymer matrix and FRs, expensive and complicated fabrication processes, limitations of raw material supplies and industrial scalability need to be further researched. In conclusion, these FRs offer a promising path toward safer, more effective, per- and polyfluoroalkyl substances (PFAS)-free and more sustainable flame-resistant polymer composites in key industrial sectors.</div></div>","PeriodicalId":34525,"journal":{"name":"Composites Part C Open Access","volume":"18 ","pages":"Article 100637"},"PeriodicalIF":7.0,"publicationDate":"2025-08-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145044680","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-08-12DOI: 10.1016/j.jcomc.2025.100636
Norbert Geier
Machining-induced burrs and delamination compromise the integrity of polymer composite components reinforced by chopped carbon tows. An image-based optimisation algorithm was therefore developed that locates the ideal hole centre within the preform allowance to minimise defect risk. High-resolution images, captured under multiple lighting conditions, are processed to generate a probability map of burr and delamination formation. Then, recursive convolution yielded a matrix whose minima identified the optimal hole position. First, edge trimming experiments were conducted to determine the arguments (critical fibre cutting angle and its range) of the developed algorithm. Up-milling was confirmed to outperform down-milling, yielding an order-of-magnitude smaller burr heights and a narrower defect-critical fibre cutting angle range. Then, based on the edge trimming results, holes were circular-milled, and demonstrated that the optimised “best-case” centre reduced average contour height by 64.99 % and contour-depth by 86.51 %, while burr- and delamination-area metrics improved by 84.90 % and 77.07 %, respectively, underlying the efficiency and importance of the proposed method. Implemented at TRL 4 with standard CNC equipment and open-source Python scripts, the method offers a practical framework for integrating burr- and delamination minimisation into CFRP component design and manufacturing process planning.
{"title":"Fibre-orientation-driven defect probability mapping for machining-induced delamination and burr minimisation in carbon fibre-reinforced polymer (CFRP) composites","authors":"Norbert Geier","doi":"10.1016/j.jcomc.2025.100636","DOIUrl":"10.1016/j.jcomc.2025.100636","url":null,"abstract":"<div><div>Machining-induced burrs and delamination compromise the integrity of polymer composite components reinforced by chopped carbon tows. An image-based optimisation algorithm was therefore developed that locates the ideal hole centre within the preform allowance to minimise defect risk. High-resolution images, captured under multiple lighting conditions, are processed to generate a probability map of burr and delamination formation. Then, recursive convolution yielded a matrix whose minima identified the optimal hole position. First, edge trimming experiments were conducted to determine the arguments (critical fibre cutting angle and its range) of the developed algorithm. Up-milling was confirmed to outperform down-milling, yielding an order-of-magnitude smaller burr heights and a narrower defect-critical fibre cutting angle range. Then, based on the edge trimming results, holes were circular-milled, and demonstrated that the optimised “best-case” centre reduced average contour height by 64.99 % and contour-depth by 86.51 %, while burr- and delamination-area metrics improved by 84.90 % and 77.07 %, respectively, underlying the efficiency and importance of the proposed method. Implemented at TRL 4 with standard CNC equipment and open-source Python scripts, the method offers a practical framework for integrating burr- and delamination minimisation into CFRP component design and manufacturing process planning.</div></div>","PeriodicalId":34525,"journal":{"name":"Composites Part C Open Access","volume":"18 ","pages":"Article 100636"},"PeriodicalIF":7.0,"publicationDate":"2025-08-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144860769","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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