Adhesive‐bonded joints in glass fiber‐reinforced polymer (GFRP) composite structures give numerous benefits, such as greater flexibility, good specific strength, improved fatigue resistance, and the ability to reduce stress concentration. Consequently, adhesive‐bonded joints are considered more influential if compared to fasteners. This research investigates the effects of incorporating graphene nanoparticles (GNPs) into the adhesive layer on several aspects of adhesively bonded co‐cure (CC) single‐lap GFRP composite joints. These aspects include shear strength, flexural strength, failure mechanisms, and fractography studies. The study examined six distinct weight percentages of GNP, specifically 0.25, 0.50, 0.75, 1.0, 1.25, and 1.5 wt.%, which are considered to enhance the interfacial strength of adhesive joints. Based on the research, 0.75 wt.% of GNP single‐lap joint (SLJ) shear strength improved by 69.40% when compared to the plain matrix SLJ. This suggests excellent load transmission between adherends. In addition, the flexural strength increased by 46.57% in the specimens containing 1.25 wt.% GNP when compared to the plain matrix used to bond in SLJ. After testing, fractured specimen microscopic images were used to examine failure mechanisms. According to fractography studies, adding GNPs to the adhesive causes surfaces to become rougher, which improves the adhesion between the adhesive and the adherends.
Six distinct wt.% of GNPs were used to prepare the matrix by sonication.
Single‐lap GFRP composite joints were fabricated through a CC technique.
SLJ's maximum shear strength was found at 0.75 wt% of GNP.
SLJ's maximum flexural strength was found at 1.25 wt% of GNP.
Failure analysis was conducted using microscopes and FESEM images.


Enhancing shear and flexural strength of single lap composite joints with a graphene nanoparticle‐reinforced adhesive through a co‐curing technique

Ultrasonic welding (UW) is a well-established technique for joining thermoplastic composites and has recently been utilized in the aerospace and automotive industries. In the case of thermoset composites (TSCs), a polymer-based material placed at the welding interface called an energy director (ED) is required. The choice of the coupling layer material is linked to several requirements, such as processing temperature, high adhesion to the thermoset composites (TSCs) adherend and mechanical strength of the resulting welded joints. In this work, the authors investigated the possibility of using Poly-vinyl-butyral (PVB) reinforced with graphite nanoplatelets (GNPs) as a coupling layer in the UW of TSC adherents. The effect of GNPs aspect ratio and content on the weldability of carbon fiber-reinforced plastics (CFRP) has been investigated. PVB/GNPs nanocomposites with different filler contents (from 0.5 wt% to 2 wt%) and different aspect ratios (100 and 2100) have been fabricated. The influence of the viscoelastic properties of the flat EDs on weldability has been assessed. Finally, an improvement of lap shear strength (LSS) of 80% was found for nanocomposites with 0.5 wt% of high-aspect-ratio GNPs with respect to neat PVB. The use of high damping nanocomposites as coupling materials for TSCs paves the way for a new generation of EDs in UW.

/pdf/pvb-nanocomposites-as-energy-directors-in-ultrasonic-welding-1uwswbqz.pdf

PVB Nanocomposites as Energy Directors in Ultrasonic Welding of Epoxy Composites

The investigation of advanced joining techniques for aerospace composites is critical to ensure the aviation safety and promote the production efficiency. In this study, plain-woven PEEK and PPS meshes were selected as joining agents for an aerospace carbon fibre/epoxy laminate upon a co-cure process. An atmospheric plasma treatment was applied to the PEEK/PPS meshes for surface functionalisation, aiming to promote the chemical bonds and interactions between the meshes and the composite during the co-curing stage. The fracture resistance of the joints subject to mode I (opening) and mode II (shearing) loading conditions were conducted at both of ambient and high temperatures, which revealed excellent fracture resistance of the specimens joined by both of the plain-woven PEEK/PPS meshes. In general, the PEEK-cured joints showed more prominent fracture performance than the PPS-cured joints. In comparison to the composite joints without meshes, the mode I fracture energies of the PEEK-cured joints at ambient (22 °C) temperature and high temperature (130 °C) were 151% and 67% higher, respectively and the mode II fracture energies were 429% and 419% higher, respectively. The excellent crack resistance of the joints co-cured by the meshes was resulted from considerable peeling and tearing damage of the plain-weaved PEEK/PPS fibres during the crack propagation stage, which led to significant energy dissipation. 

Carbon fibre composite joints co-cured by advanced PEEK/PPS meshes with outstanding fracture toughness

Abstract Carbonaceous or nanocarbon nano-reinforcement nanocomposites have been found as emergent candidates for aerospace industry. Consequently, the multifunctional nanocomposites have been fabricated using marvelous nanocarbon nanostructures like graphene, carbon nanotube, fullerene, carbon black, etc. Manufacturing techniques have also been engrossed for the formation of high performance engineering nanocomposites having fine strength, heat stability, flame resistance, and other space desired features. These practices include solution, in situ, and melt procedures, on top of specific space structural design techniques, for the formation of aerospace structures. The aerospace related material property enhancements using various carbonaceous nano-reinforcements depends upon the type of nanocarbon, dimensionality, as well as inherent features of these nanostructures (in addition to the choice of manufacturing methods). Furthermore, carbon nano-reinforcements have been filled, besides carbon fibers, in the epoxy matrices. Nanocarbon coated carbon fibers have been filled in epoxy resins to form the high performance nanomaterials for space structures. The engineering features of these materials have been experiential appropriate for the aerospace structures. Further research on these nanomaterials may be a key towards future opportunities in the aero systems. Additionally, the explorations on structure-property relationships of the carbonaceous nanocomposites have been found indispensable for the development of advanced aerospace structures.

Leading-Edge Polymer/Carbonaceous Nano-Reinforcement Nanocomposites—Opportunities for Space Sector

The development of advanced joining methods for carbon fibre/epoxy composites is critical for aerospace applications. Herein, advanced PEEK/PPS meshes were used to join carbon fibre/epoxy composites upon a novel co-curing process. The meshes were surface-activated upon an atmospheric plasma technique, which largely promoted the chemical interactions between the meshes and the composite epoxy matrix. The quasi-static joint strengths at both of 22 °C and 130 °C and fatigue loading resistance of the composite joints were evaluated using a single-lap joint test and the corresponding failure mechanisms were investigated. Encouragingly, the lap-shear strengths and fatigue resistance of the PEEK/PPS mesh-joined composites were larger than that of their counterparts bonded by an aerospace adhesive. Subsequent analysis on the failure surfaces proved PEEK/PPS fibre damage and epoxy crack were the main failure mechanisms of the PEEK/PPS co-cured joints. This work proposed a novel method for the production of robust aerospace joints by co-cure joining the composites using advanced PEEK/PPS meshes. 

Significantly enhanced joint strength and fatigue life of aerospace composite joints by using novel PEEK/PPS woven meshes as joining agent

In this study, an aerospace thermosetting composite was co-curing joined by Polyether-ether-ketone (PEEK) and Polyethylenimine (PEI) films, with an aim of developing advanced composite joints. The semi-crystalline PEEK films were surface activated upon a UV-irradiation technique to obtain a strong film–composite interface, while the amorphous PEI films could be directly used. The fracture behaviour of the composite joints was evaluated and compared with benchmark aerospace adhesive joints. The experimental results proved remarkable mode-I and mode-II fracture resistance of the PEEK co-cured joints at 22 °C and 130 °C, while the PEI co-cured joints exhibited excellent mode-I fracture resistance at 22 °C and mode-II fracture resistance in both testing temperature cases. Extensive elongation, tearing and fracture of the PEEK/PEI plastics were proved to be the main mechanisms for toughness enhancement. Overall, this work had successfully demonstrated the effectiveness of developing advanced composite joints via a co-curing process using high-performance thermoplastic films. 

On the application of strong thermoplastic–thermoset interactions for developing advanced aerospace-composite joints

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On the application of strong thermoplastic–thermoset interactions for developing advanced aerospace-composite joints