Enhanced interphase between epoxy matrix and carbon fiber with carbon nanotube-modified silane coating

The performance of carbon fiber-reinforced composites is dependent to a great extent on the properties of fiber-matrix interface. To improve the interfacial properties in carbon fiber/epoxy composites, we directly introduced graphene oxide (GO) sheets dispersed in the fiber sizing onto the surface of individual carbon fibers. The applied graphite oxide, which could be exfoliated to single-layer GO sheets, was verified by atomic force microscope (AFM). The surface topography of modified carbon fibers and the distribution of GO sheets in the interfacial region of carbon fibers were detected by scanning electron microscopy (SEM). The interfacial properties between carbon fiber and matrix were investigated by microbond test and three-point short beam shear test. The tensile properties of unidirectional (UD) composites were investigated in accordance with ASTM standards. The results of the tests reveal an improved interfacial and tensile properties in GO-modified carbon fiber composites. Furthermore, significant enhancement of interfacial shear strength (IFSS), interlaminar shear strength (ILSS), and tensile properties was achieved in the composites when only 5 wt % of GO sheets introduced in the fiber sizing. This means that an alternative method for improving the interfacial and tensile properties of carbon fiber composites by controlling the fiber-matrix interface was developed. Such multiscale reinforced composites show great potential with their improved mechanical performance to be likely applied in the aerospace and automotive industries.

Traditional fibre-reinforced composite materials with excellent in-plane properties fare poorly when out-of-plane through-thickness properties are important. Composite architectures with fibres designed orthogonal to the two-dimensional (2D) layout in traditional composites could alleviate this weakness in the transverse direction, but all of the efforts so far have only produced limited success. Here, we unveil an approach to the 3D composite challenge, without altering the 2D stack design, on the basis of the concept of interlaminar carbon-nanotube forests that would provide enhanced multifunctional properties along the thickness direction. The carbon-nanotube forests allow the fastening of adjacent plies in the 3D composite. We grow multiwalled carbon nanotubes on the surface of micro-fibre fabric cloth layouts, normal to the fibre lengths, resulting in a 3D effect between plies under loading. These nanotube-coated fabric cloths serve as building blocks for the multilayered 3D composites, with the nanotube forests providing much-needed interlaminar strength and toughness under various loading conditions. For the fabricated 3D composites with nanotube forests, we demonstrate remarkable improvements in the interlaminar fracture toughness, hardness, delamination resistance, in-plane mechanical properties, damping, thermoelastic behaviour, and thermal and electrical conductivities making these structures truly multifunctional.