Tomas Katafiasz, Imperial College London
Hybrid Fibre Composites for Delamination Resistance and Cost Saving
2nd Year PhD Student: Tomas Katafiasz 8th December 2015, Cyclitech 2015, Brussels
Presentation Structure 1. Manufacturing Hybrid Fibre Composites 2. Interlaminar Shear 3. Test Regime – Short Beam Shear Test 4. Results 5. Post-Analysis – Fractography 6. Conclusions
Trek Domane (Carbon)
Manufacturing Hybrid Fibre Composites Professional background
Structure of presentation – Table of contents
Hybridisation of Composites “Two or more chemically distinct fibre types bonded using a common adhesive system” In this case glass fibre and carbon fibre
Czel, G. et al., 2012
Carbon Fibre Woven Spread Tow Developed in Japan in the 1990s Flat tows instead of circular tows – thinner, lighter, stronger! Fibre type: T700S Toray Carbon
Woven Glass Fibre Much cheaper than carbon fibre! Structurally superior compared to common E-Glass Fibre type: S2-Glass
Resin Film Infusion Processing allows easy manipulation of fibre / resin type and quantity
Glass Resin Carbon Glass Carbon Resin Glass
Interlaminar Shear Single fibre tension test
Delamination in Carbon Bike Forks
Cross section:
Interlaminar Shear
Interlaminar Shear τ12 = τ21 for 0°/90° woven laminates
Test Regime Short Beam Shear Test Summary of literature
• Carbon fibre spread tow hybrids: • Cheaper than standard carbon (can be combined with less expensive materials, where it provides most structural integrity) • Better drapability than standard carbon fibres • Better mechanical performance across the board • Smoother surface finish than standard carbon
• Ballistic with spread tow hybrids: • Maintain ballistic resistance while improving structural integrity of components
Short Beam Shear Test Rig British Standard ISO: 14130:1998
Short Beam Shear Test Rig
Short Beam Shear Test Rig
L O A D
Short Beam Shear Test Rig
L O A D
Summary of literature • Carbon fibre spread tow hybrids: • Cheaper than standard carbon (can be combined with less expensive materials, where it provides most structural integrity) • Better drapability than standard carbon fibres • Better mechanical performance across the board • Smoother surface finish than standard carbon
Results
• Ballistic with spread tow hybrids: • Maintain ballistic resistance while improving structural integrity of components
Hybrid vs Non-Hybrid
Hybrid vs Non-Hybrid + Thick Carbon
Thermoset vs Thermoplastic
Post-Analysis Fractography Professional background
Hybrid vs Non-Hybrid + Thick Carbon
Carbon ‘Thin’ – Spread Tow
cusps
cusps
Carbon ‘Thin’ – Spread Tow
Hybrid vs Non-Hybrid + Thick Carbon
Glass ‘Thick’
voids
voids
Glass ‘Thick’
voids
voids
voids
Hybrid vs Non-Hybrid + Thick Carbon
Hybrid – Carbon ‘Thin’ / Glass ‘Thick’
Hybrid – Carbon ‘Thin’ / Glass ‘Thick’
Hybrid vs Non-Hybrid + Thick Carbon
Carbon ‘Thick’
cusps cusps
cusps
Carbon ‘Thick’
Thermoset vs Thermoplastic
Carbon ‘Non-Crimp’ - Thermoset
cusps
Carbon ‘Non-Crimp’ - Thermoset
Thermoset vs Thermoplastic
Carbon ‘Non-Crimp’ - Thermoplastic
Carbon ‘Non-Crimp’ - Thermoplastic
Professional background
Conclusions
Conclusions
Conclusions
• Carbon / glass fibre hybrids show very good delamination resistance compared to traditional thick carbon composite • Cost savings are already possible, once more is understood about the mechanical performance of hybrids, a range of cheaper options will become available Hybrids are a hot topic in research at the moment! • Thermoplastic options must be investigated further to enable recyclable components Carbon ‘non-crimp’ thermoset: 50MPa Carbon ‘non-crimp’ thermoplastic: 41MPa
Industrial Partners
Tomas Katafiasz
[email protected]
With thanks to: Mohsin, M. A. A., Iannucci, L. and Greenhalgh, E.
2nd Year PhD Student: Tomas Katafiasz 8th December 2015, Cyclitech 2015, Brussels
Presentation Structure 1. Manufacturing Hybrid Fibre Composites 2. Interlaminar Shear 3. Test Regime – Short Beam Shear Test 4. Results 5. Post-Analysis – Fractography 6. Conclusions
Trek Domane (Carbon)
Manufacturing Hybrid Fibre Composites Professional background
Structure of presentation – Table of contents
Hybridisation of Composites “Two or more chemically distinct fibre types bonded using a common adhesive system” In this case glass fibre and carbon fibre
Czel, G. et al., 2012
Carbon Fibre Woven Spread Tow Developed in Japan in the 1990s Flat tows instead of circular tows – thinner, lighter, stronger! Fibre type: T700S Toray Carbon
Woven Glass Fibre Much cheaper than carbon fibre! Structurally superior compared to common E-Glass Fibre type: S2-Glass
Resin Film Infusion Processing allows easy manipulation of fibre / resin type and quantity
Glass Resin Carbon Glass Carbon Resin Glass
Interlaminar Shear Single fibre tension test
Delamination in Carbon Bike Forks
Cross section:
Interlaminar Shear
Interlaminar Shear τ12 = τ21 for 0°/90° woven laminates
Test Regime Short Beam Shear Test Summary of literature
• Carbon fibre spread tow hybrids: • Cheaper than standard carbon (can be combined with less expensive materials, where it provides most structural integrity) • Better drapability than standard carbon fibres • Better mechanical performance across the board • Smoother surface finish than standard carbon
• Ballistic with spread tow hybrids: • Maintain ballistic resistance while improving structural integrity of components
Short Beam Shear Test Rig British Standard ISO: 14130:1998
Short Beam Shear Test Rig
Short Beam Shear Test Rig
L O A D
Short Beam Shear Test Rig
L O A D
Summary of literature • Carbon fibre spread tow hybrids: • Cheaper than standard carbon (can be combined with less expensive materials, where it provides most structural integrity) • Better drapability than standard carbon fibres • Better mechanical performance across the board • Smoother surface finish than standard carbon
Results
• Ballistic with spread tow hybrids: • Maintain ballistic resistance while improving structural integrity of components
Hybrid vs Non-Hybrid
Hybrid vs Non-Hybrid + Thick Carbon
Thermoset vs Thermoplastic
Post-Analysis Fractography Professional background
Hybrid vs Non-Hybrid + Thick Carbon
Carbon ‘Thin’ – Spread Tow
cusps
cusps
Carbon ‘Thin’ – Spread Tow
Hybrid vs Non-Hybrid + Thick Carbon
Glass ‘Thick’
voids
voids
Glass ‘Thick’
voids
voids
voids
Hybrid vs Non-Hybrid + Thick Carbon
Hybrid – Carbon ‘Thin’ / Glass ‘Thick’
Hybrid – Carbon ‘Thin’ / Glass ‘Thick’
Hybrid vs Non-Hybrid + Thick Carbon
Carbon ‘Thick’
cusps cusps
cusps
Carbon ‘Thick’
Thermoset vs Thermoplastic
Carbon ‘Non-Crimp’ - Thermoset
cusps
Carbon ‘Non-Crimp’ - Thermoset
Thermoset vs Thermoplastic
Carbon ‘Non-Crimp’ - Thermoplastic
Carbon ‘Non-Crimp’ - Thermoplastic
Professional background
Conclusions
Conclusions
Conclusions
• Carbon / glass fibre hybrids show very good delamination resistance compared to traditional thick carbon composite • Cost savings are already possible, once more is understood about the mechanical performance of hybrids, a range of cheaper options will become available Hybrids are a hot topic in research at the moment! • Thermoplastic options must be investigated further to enable recyclable components Carbon ‘non-crimp’ thermoset: 50MPa Carbon ‘non-crimp’ thermoplastic: 41MPa
Industrial Partners
Tomas Katafiasz
[email protected]
With thanks to: Mohsin, M. A. A., Iannucci, L. and Greenhalgh, E.
