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- PublikationMultiscale characterisation of staple carbon fibre-reinforced polymers(MDPI, 06.11.2023) Zweifel, Lucian; Kupski, Julian; Dransfeld, Clemens; Caglar, Baris; Baz, Stephan; Cessario, Damian; Gresser, Götz T.; Brauner, Christian [in: Journal of Composites Science]The aim of this study was to characterise the microstructural organisation of staple carbon fibre-reinforced polymer composites and to investigate their mechanical properties. Conventionally, fibre-reinforced materials are manufactured using continuous fibres. However, discontinuous fibres are crucial for developing sustainable structural second-life applications. Specifically, aligning staple fibres into yarn or tape-like structures enables similar usage to continuous fibre-based products. Understanding the effects of fibre orientation, fibre length, and compaction on mechanical performance can facilitate the fibres’ use as standard engineering materials. This study employed methods ranging from microscale to macroscale, such as image analysis, X-ray computed tomography, and mechanical testing, to quantify the microstructural organisations resulting from different alignment processing methods. These results were compared with the results of mechanical tests to validate and comprehend the relationship between fibre alignment and strength. The results show a significant influence of alignment on fibre orientation distribution, fibre volume fraction, tortuosity, and mechanical properties. Furthermore, different characteristics of the staple fibre tapes were identified and attributed to kinematic effects during movement of the sliver alignment unit, resulting in varying tape thicknesses and fuzzy surfaces.01A - Beitrag in wissenschaftlicher Zeitschrift
- PublikationTailored flexibility in inherently brittle epoxy-based composites through gradient interphase formation with bio-based thermoplastic elastomer grades(Elsevier, 05.07.2023) Zweifel, Lucian; Kupski, Julian; Brauner, Christian [in: Composites Part A: Applied Science and Manufacturing]This study focuses on tailoring elastic behaviour in an inherently brittle epoxy-based fibre-reinforced composite material formed through a gradient interphase with a bio-based thermoplastic elastomer. The fast-curing epoxy Araldite LY3585/Aradur 3475 was tested with two bio-based Pebax block copolymer grades. First, the interphase was characterised via optical hot-stage microscopy and Raman spectroscopy. The analysis unveiled pronounced diffusion followed by a reaction-induced phase separation, which led to the formation of an interphase with a thickness exceeding 200 μm at the temperatures associated with the curing process. Second, composite laminates were fabricated through a combined process of fused filament fabrication and vacuum infusion, incorporating a flexible domain with variable stiffness properties. The material architecture exhibited brittle-to-ductile behaviour at the micrometre scale, with tailored flexible response under bending and stiff behaviour in tension. Consequently, the study anticipates using multi-scale toughened material structures for more efficient generative design concepts.01A - Beitrag in wissenschaftlicher Zeitschrift
- PublikationExperimental and numerical development on multi-material joining technology for sandwich-structured composite materials(MDPI, 12.10.2021) Zweifel, Lucian; Zhilyaev, Igor; Brauner, Christian; Rheme, Martin; Eckhard, Gregor; Bersier, Valentin; Glavaški, Slobodan; Pfeiffer, Ricardo [in: Materials]Creating connection points for sandwich-structured composites without losing technical performance is key to realising optimal lightweight structures. The patented LiteWWeight® technology presents cost-effective connections on sandwich panels in a fraction of a few seconds without predrilling. Ultrasonic equipment is used to insert a thermoplastic fastener into the substrate material and partially melt it into the porous internal structure. This creates a highly interlocked connection (connection strength is above 500 N) suitable for semi-structural applications. This study focused on the simulation and experimental validation of this process, mainly on the interaction between the pin and the substrate material during the joining process. The dynamic thermo-mechanical model showed reasonable agreement with experimental methods such as process data, high-speed camera monitoring or computed tomography and allowed the prediction of the connection quality by evaluation of the degree of interlock. The connection strength prediction by the developed model was validated within several various process setups, resulting in a prediction accuracy between 94–99% depending on the setup.01A - Beitrag in wissenschaftlicher Zeitschrift
- PublikationInvestigation of the interphase mechanisms and welding behaviour of fast-curing epoxy based composites with co-cured thermoplastic boundary layers(Elsevier, 12/2020) Zweifel, Lucian; Brauner, Christian [in: Composites Part A: Applied Science and Manufacturing]This study focuses on investigating thermoplastic polymers and their interphase behaviour with the fast-curing epoxy system Araldite LY3585/Aradur 3475. The three compatible thermoplastic polymers poly(methyl methacrylate) (PMMA), amorphous polyamide (PA12TR90), and poly(hydroxy ether) (phenoxy) were chosen to determine their affinity and interphase formation with the epoxy system. The final concept involves the use of a thermoplastic as a boundary layer on top of the epoxy to establish a connection between two joined parts by resistance welding. The thermoplastic boundary layer was generated by co-curing during the curing process. The experiments resulted in a high compatibility between phenoxy and PMMA in the selected epoxy system which leads to excellent mechanical properties after welding. Phenoxy showed the strongest joints, with an average lap shear strength of 25 MPa, demonstrating the high potential of this joining technique for industrial applications in the automotive and wind energy fields.01A - Beitrag in wissenschaftlicher Zeitschrift
- PublikationCo-curing behaviour of thermoset composites with a thermoplastic boundary layer for welding purposes(SAGE, 17.03.2020) Brauner, Christian; Nakouzi, Sawsane; Zweifel, Lucian; Tresch, Jens [in: Advanced Composites Letters]The primary objective of this study is to determine the interphase behaviour of a thermoset epoxy resin that is commercially used for carbon fibre–reinforced composite materials in aerospace structures and a suitable thermoplastic material that can be used as a boundary layer. The thermoplastic boundary layer will be used for welding purposes to join structural components with a fraction of the effort compared to conventional gluing processes. In this study, the interphase formation of an epoxy resin with several thermoplastic materials, namely, polyetheretherketone, polyvinylidenfluoride, polyphenylensulfide and polyetherimide (PEI), is studied via hot-stage microscope experiments. Based on this study, PEI was selected, and a detailed study was performed to determine the dependency of dissolution, diffusion and phase separation mechanisms under various isothermal conditions. Additionally, the welding behaviour was investigated by a resistance welding rig whereby the process parameters were statistically varied to optimize the lap shear strength. The results of this study will enable a statement about the interphase development, the morphology and the mechanical properties which is a key element of fully understanding the process.01A - Beitrag in wissenschaftlicher Zeitschrift