1. Experimental investigation of toughening carbon fibre/epoxy composites with graphene/phenoxy fibres
- Author
-
Lin, Han, Sampson, William, and Potluri, Venkata
- Subjects
Composites ,Toughening ,Fibres ,Polymer Nanocomposites ,Graphene - Abstract
This thesis reports a toughening concept for carbon fibre reinforced polymer composites using continuous thermoplastic nanocomposite fibres in which dissolvable phenoxy was used as a toughener for the epoxy matrix and at the same time as a carrier to deliver graphite nanoplatelets (GNP) into desired positions of composites. Nanocomposites containing different GNP contents were prepared via masterbatch dilution method, and these were melt spun and drawn into fibres at varying take-up speeds. Structural characterisation revealed that the dispersion of GNP worsened with both increasing GNP content and take-up speed, especially in the fibre core region. Moreover, due to the strong shear stress exerted by the spinneret wall, GNP in the outer layer of the fibre showed a tangential orientation, which was absent in the fibre centre. As a consequence, the Young's modulus, which is a low-strain property, increased with both GNP content and take-up speed, while the tensile strength remained relatively unchanged because it was more sensitive to the GNP agglomeration. Theoretical analysis with simple rule of mixtures and shear-lag theory suggested the enhanced Young's modulus originated from the increased orientation degree (η₀) of GNP at high take-up speeds, which was not attainable from SEM/TEM characterisation. Moreover, the η₀ was found to be in good agreement with the normalised areal ratio (ratio of the area of the imaginary fibre sheath layer to the whole cross-sectional area) of fibres at each take-up speed, which could indicate the variation in the reinforcing efficiency of GNP in the fibre core and sheath layer due to the different dispersion qualities of GNP in these two regions. The electrical percolation threshold was 8.0 wt% for compression moulded plates, which was relatively lower than the rheological one (8.8 wt%) due to the fact that less GNP was required to form a conductive network that can be detected by the static electrical measurements. Conversely, fibres with the same GNP content were not conductive because of the orientation, separation and aggregation of GNP upon drawing. The dissolution behaviour of pure phenoxy and GNP/phenoxy fibres was studied in model systems using optical microscopy. Results showed that GNP/phenoxy nanocomposite fibres took longer than pure phenoxy fibres to completely dissolve, probably because the tangentially oriented GNP in the outer layer of the fibre hindered the interdiffusion of phenoxy chains and RTM6-2 precursors. The dissolution study also suggested that too high a dissolution temperature could lead to a premature gelation of the epoxy resin and that thinner fibres were preferred for use in composites. As a proof of concept, GNP/phenoxy fibres were 3D braided with carbon fibre (CF) to produce hybrid strands, followed by resin infusion to prepare composite laminates. Both phenoxy and GNP improved the Mode I interlaminar fracture toughness (GIc) of composites although phenoxy exhibited a more pronounced toughening effect. This was attributed mainly to the significantly intensified CF breakage and pullout in regions where pure phenoxy or GNP/phenoxy fibres initially located, as evidenced by the SEM observation on the fracture surfaces of composites. Crack deflection induced by the phase-inverted RTM6-2 nodules in the presence of relatively high local concentration of phenoxy, crack pinning caused by GNP and GNP pullout/separation were also proposed as the toughening mechanisms.
- Published
- 2023