A review on carbon fiber-reinforced hierarchical composites: mechanical performance, manufacturing process, structural applications and allied challenges

Abstract

The utilization of carbonaceous reinforcement-based polymer matrix composites in structural applications has become a hot topic in composite research. Although conventional carbon fiber-reinforced polymer composites (CFRPs) have revolutionized the composite industry by offering unparalleled features, they are often plagued with a weak interface and lack of toughness. However, the promising aspects of carbon fiber-based fiber hybrid composites and hierarchical composites can compensate for these setbacks. This review provides a meticulous landscape and recent progress of polymer matrix-based different carbonaceous (carbon fiber, carbon nanotube, graphene, and nanodiamond) fillers reinforced composites’ mechanical properties. First, the mechanical performance of neat CFRP was exhaustively analyzed, attributing parameters were listed down, and CFRPs’ mechanical performance barriers were clearly outlined. Here, short carbon fiber-reinforced thermoplastic composite was distinguished as a prospective material. Second, the strategic advantages of fiber hybrid composites over conventional CFRP were elucidated. Third, the mechanical performance of hierarchical composites based on carbon nanotube (1D), graphene (2D) and nanodiamond (0D) was expounded and evaluated against neat CFRP. Fourth, the review comprehensively discussed different fabrication methods, categorized them according to performance and suggested potential future directions. From here, the review sorted out three-dimensional printing (3DP) as the most futuristic fabrication method and thoroughly delivered its pros and cons in the context of the aforementioned carbonaceous materials. To conclude, the structural applications, current challenges and future prospects pertinent to these carbonaceous fillers reinforced composite materials were elaborated.

The Design of 4D‐Printed Hygromorphs: State‐of‐the‐Art and Future Challenges

“…Here, such reviews for hydrogels [182] and polymer/composites are given. [183][184][185] The printing parameters can influence the stiffness of the structure. Hence, understanding their influence is the key to make sure the stiffness measured is representative of the one the material provides to the hygromorph.…”

High‐performance hierarchical composites based on polyamide 6, carbon fiber and graphene oxide

“…Some researchers [ 8,11,18–22 ] have evaluated the influence of GO coating on the mechanical properties of PA6/CFs and PA66/CFs composites. For instance, Cho et al [ 20 ] developed composites of polyamide 66 (PA66) and CFs with GO functionalized with acyl chloride (AGO) and carbon nanotubes (CNTs) through in situ polymerization.…”

“…[12,18] Furthermore, oxygen-containing functional groups in GO provide unrivaled dispersibility, solubility, and stability of the nanofiller. [19] Some researchers [8,11,[18][19][20][21][22] have evaluated the influence of GO coating on the mechanical properties of PA6/CFs and PA66/CFs composites. For instance, Cho et al [20] developed composites of polyamide 66 (PA66) and CFs with GO functionalized with acyl chloride (AGO) and carbon nanotubes (CNTs) through in situ polymerization.…”

“…[ 12,18 ] Furthermore, oxygen‐containing functional groups in GO provide unrivaled dispersibility, solubility, and stability of the nanofiller. [ 19 ]…”

Ultrahigh strength and modulus of polyimide-carbon nanotube based carbon and graphitic fibers with superior electrical and thermal conductivities for advanced composite applications

“…Carbon fibers (CFs) have been predominantly used as reinforcing materials of composites. Among various applications, CFs have attracted significant attention in aerospace and defense industry because of their exceptional mechanical properties [1][2][3][4]. In regard to their tensile properties, polyacrylonitrile (PAN)-based CFs with high strength and pitch-based CFs with high modulus are well known in CF industry.…”