Detecting Multi-Scale Defects in Material Extrusion Additive Manufacturing of Fiber-Reinforced Thermoplastic Composites: A Review of Challenges and Advanced Non-Destructive Testing Techniques.

Additive manufacturing (AM) defects present significant challenges in fiber-reinforced thermoplastic composites (FRTPCs), directly impacting both their structural and non-structural performance. In structures produced through material extrusion-based AM, specifically fused filament fabrication (FFF), the layer-by-layer deposition can introduce defects such as porosity (up to 10-15% in some cases), delamination, voids, fiber misalignment, and incomplete fusion between layers. These defects compromise mechanical properties, leading to reduction of up to 30% in tensile strength and, in some cases, up to 20% in fatigue life, severely diminishing the composite's overall performance and structural integrity.

Super-Resolution Processing of Synchrotron CT Images for Automated Fibre Break Analysis of Unidirectional Composites.

Fibre breaks govern the strength of unidirectional composite materials under tension. The progressive development of fibre breaks is studied using in situ X-ray computed tomography, especially with synchrotron radiation. However, even with synchrotron radiation, the resolution of the time-resolved in situ images is not sufficient for a fully automated analysis of continuous mechanical deformations.

A Review of Electrospun Nanofiber Interleaves for Interlaminar Toughening of Composite Laminates.

Recently, polymeric nanofiber veils have gained lot of interest for various industrial and research applications. Embedding polymeric veils has proven to be one of the most effective ways to prevent delamination caused by the poor out-of-plane properties of composite laminates. The polymeric veils are introduced between plies of a composite laminate, and their targeted effects on delamination initiation and propagation have been widely studied.

Negative Temperature Coefficient of Resistance in Aligned CNT Networks: Influence of the Underlying Phenomena.

Temperature dependence of electrical conductivity/resistivity of CNT networks (dry or impregnated), which is characterised by a temperature coefficient of resistance (TCR), is experimentally observed to be negative, especially for the case of aligned CNT (A-CNT). The paper investigates the role of three phenomena defining the TCR, temperature dependence of the intrinsic conductivity of CNTs, of the tunnelling resistance of their contacts, and thermal expansion of the network, in the temperature range 300-400 K. A-CNT films, created by rolling down A-CNT forests of different length and described in Lee et al.

Uncertainties in Electric Circuit Analysis of Anisotropic Electrical Conductivity and Piezoresistivity of Carbon Nanotube Nanocomposites.

Electrical conductivity and piezoresistivity of carbon nanotube (CNT) nanocomposites are analyzed by nodal analysis for aligned and random CNT networks dependent on the intrinsic CNT conductivity and tunneling barrier values. In the literature, these parameters are assigned with significant uncertainty; often, the intrinsic resistivity is neglected. We analyze the variability of homogenized conductivity, its sensitivity to deformation, and the validity of the assumption of zero intrinsic resistivity.

Fatigue of hybrid fibre-reinforced plastics.

Understanding the fatigue behaviour of hybrid fibre-reinforced plastics is desirable for exploiting their features in safe, durable and reliable industrial components. The fatigue performance of hybrid composites has not been extensively investigated yet. The paper presents an overview of the available knowledge on the fatigue of hybrid fibre-reinforced plastics, and, more specifically, reports the fatigue behaviour of a quasi-isotropic pseudo-ductile all-carbon fibre interlayer hybrid composite by experimental measurements and observations, with emphasis on the damage development.

Influence of the Nanostitch Sensor Embedment on the Fibrous Microstructure of Glass Fiber Prepreg Laminates.

Changes in the fibrous microstructure in glass fiber/epoxy prepreg quasi-isotropic laminates after the introduction of embedded sensors in the form of "nanostitch" as interleaves are investigated using 3D imaging with synchrotron radiation computer tomography (SRCT). Nanostitch interfaces are created by aligned carbon nanotubes (CNTs) with two different morphologies. The laminates are fabricated using an autoclave.

Homogenisation of the Local Thermal Conductivity in Injection-Moulded Short Fibre Reinforced Composites.

This paper deals with predicting the effective thermal conductivity (ETC) of injection-moulded short fibre reinforced polymers (SFRPs) using two different homogenisation schemes: a scheme based on the dielectric theory for pseudo-oriented inclusions and a two-step homogenisation model based on the mean-field homogenisation approach. In both cases, the fibre orientation tensor (FOT) obtained from Autodesk Moldflow simulation was used. The Moldflow FOT predictions were validated via structure tensor analysis of micro-computed X-ray tomography (micro-CT) scans of the part.

Large datasets of single carbon and glass fibre mechanical properties obtained with automated testing equipment.

This data article presents fibre mechanical properties acquired using automated single fibre tensile testing equipment. The raw data consists of the fibre diameter, gauge length and load-displacement diagrams. A total of 690 fibres were tested across four carbon and one glass fibre type.

A dataset of micro-scale tomograms of unidirectional glass fiber/epoxy and carbon fiber/epoxy composites acquired via synchrotron computed tomography during tensile loading.

We have performed synchrotron computed tomography on two different fiber-reinforced composites while they were being continuously loaded in 0° tension. One material is a glass/epoxy laminate and the other is a carbon/epoxy laminate. The voxel size is 1.

A dataset of void characteristics in multidirectional carbon fiber/epoxy composite laminates, obtained using X-ray micro-computed tomography.

In the current data article, we present detailed characteristics of voids in carbon/epoxy composite laminates, along with the original image stacks obtained via X-ray micro-Computed Tomography (micro-CT). Five different lay-ups are produced with altering the recommended cure cycle in order to intentionally induce voids in the material. For each lay-up, an image stack (consisting of tomographic slices) and a dataset are provided.