Optimization study on wet electrostatic powder coating process to manufacture UHMWPE/LDPE towpregs

In the present study, an attempt has been made to coat the non-conductive Ultra-high Molecular Weight Polyethylene (UHMWPE) fibers with Low-Density Polyethylene (LDPE) powder. In order to enable the deposition of electrostatically charged LDPE powder onto the fiber surface, UHMWPE fibers are dipped into a surface modification bath to impart momentary conductivity. Further, Box Behnken’s experimental design is used to optimize the processing parameters for Fiber Volume Fraction (Vf) for this wet electrostatic spray coating process. An experimental multi-parametric equation is acquired through response surface methodology to ascertain the association amid the process parameters such as processing temperature (A), conveying air pressure (B), and gun nozzle angle (C) on the output response of Vf. The process parametric values for A, B, and C are varied from 225°C to 245°C, 0.2 bar to 0.4 bar, and 0° to 120° respectively. The Vf obtained is in the range of 37.02%–56.28% depending on the combination of process parametric values. Powder pick-up increases with an increase in the gun nozzle angle. An increase in conveying air pressure and temperature of the hot air oven leads to an increase in powder deposition. The values predicted from the model are observed to be in close proximity (94.59%) to the experimental results. Gun nozzle angle is the principal parameter affecting the matrix deposition on the fiber surface in comparison to other process parameters.

Shear Response of Recycled Aggregates Concrete Deep Beams Containing Steel Fibers and Web Openings

Replacement of natural aggregates (NAs) with recycled concrete aggregates (RCAs) in complex reinforced concrete (RC) structural elements, such as deep beams with openings, supports environmental sustainability in the construction industry. This research investigates the shear response of RC deep beams with openings made with 100% RCAs. It also examines the effectiveness of using steel fibers as a replacement to the minimum conventional steel stirrups in RCA-based deep beams with web openings. A total of seven RC deep beams with a shear span-to-depth ratio (a/h) of 0.8 were constructed and tested. A circular opening with an opening height-to-depth ratio (h0/h) of 0.3 was placed in the middle of each shear span. Test parameters included the type of the coarse aggregate (NAs and RCAs), steel fiber volume fraction (vf = 1, 2, and 3%), and presence of the minimum conventional steel stirrups. The deep beam specimens with web openings made with 100% RCAs exhibited 13 to 18% reductions in the shear capacity relative to those of their counterparts made with NAs. The inclusion of conventional steel stirrups in RC deep beams with openings was less effective in improving the shear response when 100% RCAs was used. The addition of steel fibers remarkably improved the shear response of the tested RCA-based beams. The gain in the shear capacity of the RCA-based beams caused by the inclusion of steel fibers was in the range of 39 to 84%, whereas the use of conventional steel stirrups resulted in 18% strength gain. The use of 1% steel fiber volume fraction in the RCA-based beam with openings without steel stirrups was sufficient to restore 96% of the original shear capacity of the NA-based beam with conventional steel stirrups. The shear capacities obtained from the tests were compared with predictions of published analytical models. The predicted-to-measured shear capacity was in the range of 0.71 to 1.49.

Continuous Fiber-Reinforced Aramid/PETG 3D-Printed Composites with High Fiber Loading through Fused Filament Fabrication

Recent development in the field of additive manufacturing, also known as three-dimensional (3D) printing, has allowed for the incorporation of continuous fiber reinforcement into 3D-printed polymer parts. These fiber reinforcements allow for the improvement of the mechanical properties, but compared to traditionally produced composite materials, the fiber volume fraction often remains low. This study aims to evaluate the in-nozzle impregnation of continuous aramid fiber reinforcement with glycol-modified polyethylene terephthalate (PETG) using a modified, low-cost, tabletop 3D printer. We analyze how dimensional printing parameters such as layer height and line width affect the fiber volume fraction and fiber dispersion in printed composites. By varying these parameters, unidirectional specimens are printed that have an inner structure going from an array-like to a continuous layered-like structure with fiber loading between 20 and 45 vol%. The inner structure was analyzed by optical microscopy and Computed Tomography (µCT), achieving new insights into the structural composition of printed composites. The printed composites show good fiber alignment and the tensile modulus in the fiber direction increased from 2.2 GPa (non-reinforced) to 33 GPa (45 vol%), while the flexural modulus in the fiber direction increased from 1.6 GPa (non-reinforced) to 27 GPa (45 vol%). The continuous 3D reinforced specimens have quality and properties in the range of traditional composite materials produced by hand lay-up techniques, far exceeding the performance of typical bulk 3D-printed polymers. Hence, this technique has potential for the low-cost additive manufacturing of small, intricate parts with substantial mechanical performance, or parts of which only a small number is needed.

An Experimental Investigation on Suitability of Using Sisal Fibers in Reinforced Concrete Composites

Fiber reinforcement is widely used in construction engineering to improve the mechanical properties of concrete such as compressive and tensile strengths. Concrete is strong in compression but weak in tension and is a brittle material. In the construction industry, strength, durability and cost are among the major factors for selecting the suitable construction materials. During this investigation, the mechanical properties of sisal fibers reinforced concrete (SFRC) were assessed namely, flexural strength, tensile strength ad interfacial bond strength. The said properties were assessed in two types of reinforcement namely, randomly oriented sisal fibers and parallel oriented sisal fibers reinforcement. In both cases the sisal fibers were varied in volume fractions so as to establish the optimum value. The mechanical properties of flexural and tensile strengths were found to increase considerably with increasing fiber volume fractions until an optimum volume fraction is reached, thereafter, the strengths were found to decrease continuously. The prominent increment of 32.4% in flexural strength at fiber volume fraction of 2.0% parallel reinforced fiber concrete composite was observed. There was very small increment on both flexural and tensile strength for randomly oriented chopped sisal fibers reinforced concrete (SFRC). The Interfacial bond strength was found to be 0.12 N/mm2 and was observed to be prominent for chopped sisal fibers reinforced concrete specimens tested for flexural strength. During failure, fiber pull-out was observed and the composite was observed to behave in a ductile manner whereby the fibers were able to carry more load while full fracture had occurred on the specimen. The water absorption capacity of the SFRC was found to increase with increasing sisal fiber volume fraction.

Analysis of the Hybrid of Mudar/Snake Grass Fiber-Reinforced Epoxy with Nano-Silica Filler Composite for Structural Application

Natural fiber composite materials are competent materials that may replace conventional synthetic materials where the strength to weight ratio is essential. In this paper, the mechanical characteristics of composites made up of randomly oriented natural fibers (mudar fiber and snake grass fiber) with nano-silica filler are detailed for the first time. From the various literature surveys, the critical length of mudar and snake grass fiber is chosen as 40 mm and 30 mm, respectively. The test samples were prepared with a fiber content of 10%, 20%, 30%, and 40% with an equal amount of mudar and snake grass fiber. The percentage of nano-filler is maintained as constant as 3% with all the compositions. The composites showed that the highest mechanical properties were found at 30% fiber volume. The maximum tensile strength is 45 MPa, and the flexural strength is 51 MPa. The maximum impact strength is 4.5 J. Sample ID 3 provided the best results compared to other proportions. The fiber/matrix adhesion was investigated using a scanning electron microscope (SEM). These predominant mechanical properties make it easier for the implementation of the prepared composite material in structural and automotive applications.

High Strength Concrete Beams Reinforced with Hooked Steel Fibers under Pure Torsion

A study of the behavior of fibers in high-strength reinforced concrete beams is presented in this paper. Twelve reinforced concrete beams were tested under a pure torsion load. Different compressive strengths (45.2, 64.7, and 84.8 MPa) and fiber volume fractions (0, 0.25, 0.5, and 0.75) with variable spacing between transverse reinforcements have been used. It was discovered that the maximum torque of a high-strength concrete beam is increased by about 20.3, 25.6, and 27.1% when the fractional volume of fiber is increased from 0 to 0.25, 0.5 and 0.75 respectively (when the compressive strength is 45.2 MPa and the transverse reinforcement spacing is 100 mm). The test results show that the ultimate torsional strength becomes higher when the concrete compressive strength increases, and this percentage increase becomes higher with increasing steel fiber volume fraction. When the spacing between transverse reinforcements decreases from 150 to 100 mm, the ultimate torque increases by 19.9%. When the spacing between transverse reinforcements decreases from 100 to 60 mm, the ultimate torque increases by 17.0%. In these beams, the fibers’ compressive strength and volume fraction were kept constant at 45.2 MPa and 0.75, respectively. Doi: 10.28991/CEJ-2022-08-01-07 Full Text: PDF

Prediction of permeability of 5-harness satin fabric by a modified kozeny constant determined from experiments

Permeability is a critical parameter not only in flow simulation analysis but also in liquid composite molding (LCM) process. When a liquid resin is infused into a dry preform, the impregnation is mainly characterized by the permeability. The permeability of a dry preform can be obtained through theoretical and experimental methods. In the theoretical estimation of permeability, the effects of fiber arrangement as well as fabric type and form for various types of preforms are not sufficiently reflected in the calculation. Thus, there is a gap between the theoretical and experimental permeability. Recently, experimental determination has been gaining considerable attention as a mean to obtain accurate permeability values; however, it requires a number of trials. In this study, the permeability of the Hexforce G0926 5HS (5-harness satin) carbon fabric preform is estimated using representative theoretical prediction models, the Gebart and Kozeny–Carman equations. In addition to the Kozeny–Carman permeability (using the Kozeny constant values from literature), the Kozeny constant obtained through experiments was used to obtain a modified Kozeny–Carman permeability. All three calculated permeabilities were compared and verified with the fabric manufacturer’s reference value. The results showed that the modified Kozeny–Carman permeability using the experimentally determined Kozeny constant was closest to the reference value at 57% fiber volume fraction. Further, the predicted permeability was compared with other experimental permeability values from literature over the 40%–65% range of fiber volume fraction. We found that the modified Kozeny–Carman permeability once again came closest to the literature values. Finally, an optimized fitting equation was proposed to replace the Kozeny–Carman equation for predicting the permeability of Hexforce G0926 5HS carbon fabric over the 40%–65% fiber volume fraction range.

The tensile properties of weft-knitted biaxial tubular fabrics and reinforced composites

Weft-knitted biaxial tubular (WKBT) fabrics have been infiltrated via a resin film infusion technique to fabricate reinforced composites. To understand the mechanical properties of WKBT fabrics and the reinforced composites, the strength efficiency of insertion yarns and insertion fiber volume fraction are used to evaluate the tensile strength. The tensile properties of WKBT fabrics and the reinforced composites are studied in the 0° and 90° directions. The results show that both have two failure stages. The first stage is the fracture of insertion yarns which provide the main tensile strength, and the second stage is the fracture of stitch yarns which have significant effect on the tensile strength of WKBT fabrics and the reinforced composites. It is observed that the deformation behavior and failure mechanism of WKBT fabric reinforced composites are closely related to the structure of WKBT fabric, which can be used to predict the failure mode and morphology of WKBT fabric reinforced composites.

Composites Manufactured by Stereolithography

Stereolithography (SLA) is a widely utilized rapid additive manufacturing process for prototypes and proof-of-concept models with high resolution. In order to create structurally sound components using SLA, reinforcement needs to be incorporated in the UV-based resins typically used. However, the introduction of reinforcement into vat-based SLA printers has had limited success due to a host of processing challenges including the creation of a homogeneous resin mixture and UV-inhibiting constituents. The effectiveness of using a dual curing system, consisting of a photo and thermal initiator, for the additive manufacturing of carbon fiber short-fiber composites via vat photopolymerization, was investigated. The necessary processing parameters were developed that resulted in successful printing and curing of composites at a 5% fiber volume. Manufacturing with reinforcements that have different densities from the resin creates separation issues, either suspending to the top or settling to the bottom. Following the approaches discussed in this chapter, an even distribution of short fibers was achieved throughout SLA printed samples using a modified commercial printer. Separation was overcome by inducing a continuous flow of reinforced liquid resin in the printer vat during printing. This flow field adaptation allows commercial SLA printers the ability to produce composite parts with different densities of the constituents utilized.