Effect of laminae count and manufacturing methods on mechanical properties of thin‐ply woven composites

Kushwaha, Shashank; Mahrous, Mahmoud A.; Meyer, Jacob L.; Chadha, Charul; Jasiuk, Iwona M.

doi:10.1002/pc.29361

Title: Effect of laminae count and manufacturing methods on mechanical properties of thin‐ply woven composites

Journal Article · 10 December 2024 · Polymer Composites

DOI: https://doi.org/10.1002/pc.29361 · OSTI ID:2480959

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The Grainger College of Engineering, Department of Mechanical Science and Engineering University of Illinois at Urbana‐Champaign Urbana Illinois USA
The Grainger College of Engineering, Department of Civil and Environmental Engineering University of Illinois at Urbana‐Champaign Urbana Illinois USA
ATSP Innovations Houston Texas USA

Abstract Thin‐ply woven composites exhibit exceptional mechanical performance by delaying the onset of damage, making them suitable for high‐performance structural applications. This study outlines the impact of manufacturing techniques (vacuum bagging and hot pressing), ply count, and fiber waviness on the mechanical properties of aromatic thermosetting copolyester/carbon‐fiber (ATSP/CF) composites. The analysis encompasses several different ply counts, evaluating their effects on the in‐plane elastic modulus (0°–90°) and tensile strength. Results demonstrate that reducing the waviness (or crimp) ratio significantly enhances the in‐plane elastic modulus, with improvements up to 188%, highlighting the importance of fiber alignment. Vacuum bagging produced ply thicknesses from 128 to 58 μm for 1–36 plies, with in‐plane elastic moduli from 30.3 to 87.2 GPa, and 4‐ and 8‐ply samples showed approximately 40% higher stiffness than those made by hot pressing. ATSP resin with high thermal stability (up to 400°C) and recyclability was used. Furthermore, this study highlights the microstructural enhancements achieved through vacuum bagging, as revealed by scanning electron and optical microscopy, and micro‐computed tomography imaging. This paper provides insights into damage mitigation and achieving enhanced mechanical properties by controlling fiber waviness using vacuum bagging and higher ply count in thin‐ply ATSP/CF composites. Highlights Crimp ratio reduction enhances elastic in‐plane elastic modulus up to 188%. Vacuum bagging increases modulus over the hot pressing manufacturing method by 40%. Lowering thickness‐per‐ply increases failure strain from 0.8% to 1.2%. Explored the performance of a novel ATSP matrix with high recyclability and thermal stability.

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Sponsoring Organization:: USDOE

OSTI ID:: 2480959

Journal Information:: Polymer Composites, Journal Name: Polymer Composites Journal Issue: 7 Vol. 46; ISSN 0272-8397

Publisher:: Wiley Blackwell (John Wiley & Sons)Copyright Statement

Country of Publication:: United States

Language:: English

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