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Three-dimensional braided composites have become one kind of critical engineering material for applications in extreme environments. The 3D stepwise rotary braiding process is one vital technique for manufacturing preforms with high efficiency and flexibility. However, the fabric topology is decided by the combination of switch rotation directions, which affects the mechanical properties, and the full carrier configuration results in a loose four-directional structure which is supposed to be improved by adding axial yarns. Therefore, experiments are carried out to illustrate the effect of fabric topology and axial yarn condition on the compressive properties of 3D stepwise rotary braided composites. Samples with three types of fabric topologies named Type A, B, and C are prepared under four axial yarn conditions including no axial yarn addition, 12K axial yarn addition, 24K axial yarn addition, and 36K axial yarn addition, which are fabricated with braiding angles of 20°, 30° and 40°. Longitudinal and transverse compression tests are conducted, and the morphology is observed. It shows that the braiding angle has more influence on the longitudinal compressive properties than transverse compressive properties, and the effect of fabric topology and axial yarn condition depends on the braiding angle. The fabric topology affects a lot on the longitudinal compressive properties when the braiding angle is small, resulting in a gap of up to 40%. The longitudinal compressive properties are improved significantly by adding axial yarns especially for the composites with large braiding angles, making the strength more than double. With the increase in axial yarn size, the strength increment gradually decreases while the modulus declines after a certain size for smaller braiding angles.

Three-dimensional composites (3D) have potential applications in various fields due to their enhanced properties compared to conventional two-dimensional composites (2D). This study investigates the effect of different volumes of z-binder made from copper wire and E-glass fiber on the mechanical properties of 3D woven polymeric composites. The tensile, flexural, and fracture toughness behavior of four types of 3D orthogonal woven composites were studied in addition to a comparative 2D composite. The creation of the 3D orthogonal single-ply fabrics involved weaving z-binders using two different copper wire diameters, single fiber bundles, and double fiber bundles, each combined with four layers of woven E-glass fiber. The consolidation process for both 2D fabric and single-fabric 3D woven composites was executed using the hand lay-up technique. The results showed that most 3D woven composites outperformed 2D composites in terms of fracture toughness (stress intensity factor K IC and energy release rate G IC ) and flexural strain. However, a decrease in flexural strength and tensile properties was observed for all 3D composites. The specimen with a small copper diameter had the smallest decrease of 5% in tensile strength. Furthermore, a decrease of 9% and 21% was attained by reinforcing with double and single glass fiber bundle z-binders, respectively, as compared with 2D composites. The highest enhancement of 92.5% in flexural failure strain was attained with double glass fiber bundles of z-binder. The maximum improvement in K IC fracture toughness, reaching 126% and 101.5%, was observed in specimens with a single glass fiber bundle z-binder and those with a large copper wire diameter, respectively.

Resin matrix composites (RCs) have better thermal and chemical stability, so they are widely used in engineering fields. In this study, the aging process and mechanism of two different types of resin-based three-dimensional four-way braided composites (H15 and S15) under different hygrothermal aging conditions were studied. The effect of aging behavior on the mechanical properties of RCs was also studied. Three different aging conditions were studied: Case I, 40 °C Soak; Case II, 70 °C Soak; and Case III, 70 °C-85% relative humidity (RH). It was found that the hygroscopic behavior of RCs in the process of moisture-heat aging conforms to Fick’s second law. Higher temperatures and humidity lead to higher water absorption. The equilibrium hygroscopic content of H15 was 1.46% (Case II), and that of S15 was 2.51% (Case II). FT-IR revealed the different hygroscopic mechanisms of H15 and S15 in terms of aging behavior. On the whole, the infiltration behavior of water molecules is mainly exhibited in the process of wet and thermal aging. At the same time, the effect of the aging process on resin matrices was observed using SEM. It was found that the aging process led to the formation of microchannels on the substrate surface of S15, and the formation of these channels was the main reason for the better moisture absorption and lower mechanical strength of S15. At the same time, this study further found that temperature and oxygen content are the core influences on post-aging strength. The LVI experiment also showed that the structural changes and deterioration effects occurring after aging reduced the strength of the studied material.

In this paper, the energy absorption of Kevlar fiber and carbon fiber hybridized 3D woven composites under high-velocity impact loading was studied. A high-velocity impact model was established for the composites. The 3D Hashin and von Mises failure criteria were applied for the damage criteria of the yarn and matrix, and cohesive elements were inserted between them to simulate delamination. To validate the model, simulations were compared with test results. According to the results of the model, an algorithm based on artificial neural networks was also used to predict the hybridized composites for computational efficiency considerations. In the study of optimizing the energy absorption characteristics of three-dimensional woven structures, there is an optimal position and proportion of Kevlar hybridization to ensure the stiffness index of the structure. It is found that the position of Kevlar hybridization can result in considerable enhancement in the energy absorption of the target plate in the 3D woven structure. The proportion of Kevlar content affects the energy absorption of the optimal hybrid combination of the target plate. The energy absorption of the target plate can be effectively increased by adjusting the hybrid combination of different yarns under the condition that the Kevlar content proportion is constant, and the maximum energy absorption can be increased by 24.92%.

Three-dimensional woven composites have been reported to have superior fracture toughness, fatigue life and damage tolerance compared with laminated composites due to through-thickness reinforcement. These properties make them lighter replacements for traditional high-strength metals and laminated composites. This paper will present impact resistance research on three-dimensional orthogonal woven composites consisting of carbon fibers/bismaleimide resin (BMI). A series of impact tests were conducted using the gas gun technique with the impacted target of 150 mm × 150 mm × 8 mm (length × width × thickness) and the cylindrical titanium projectile. The projectile velocity ranged from 180 m/s to 280 m/s, generating different results from rebound to perforation. This paper also presents a multiscale modeling strategy to investigate the damage and failure behavior of three-dimensional woven composites. The microscale and mesoscale are identified to consider the fiber/matrix scale and the tow architecture scale respectively. The macroscale model was effective with homogenized feature. Then a combined meso-macroscale model was developed with the interface definitions for component analysis in the explicit dynamic software LS-DYNA. The presented results showed reliable interface connection and can be used to study localized composites damage at a relatively high efficiency.

Lithium (Li) metal is believed to be the \"Holy Grail\" among all anode materials for next-generation Li-based batteries due to its high theoretical specific capacity (3860 mAh/g) and lowest redox potential (−3.04 V). Disappointingly, uncontrolled dendrite formation and \"hostless\" deposition impede its further development. It is well accepted that the construction of three-dimensional (3D) composite Li metal anode could tackle the above problems to some extent by reducing local current density and maintaining electrode volume during cycling. However, most strategies to build 3D composite Li metal anode require either electrodeposition or melt-infusion process. In spite of their effectiveness, these procedures bring multiple complex processing steps, high temperature, and harsh experimental conditions which cannot meet the actual production demand in consideration of cost and safety. Under this condition, a novel method to construct 3D composite anode via simple mechanical modification has been recently proposed which does not involve harsh conditions, fussy procedures, or fancy equipment. In this mini review, a systematic and in-depth investigation of this mechanical deformation technique to build 3D composite Li metal anode is provided. First, by summarizing a number of recent studies, different mechanical modification approaches are classified clearly according to their specific procedures. Then, the effect of each individual mechanical modification approach and its working mechanisms is reviewed. Afterwards, the merits and limits of different approaches are compared. Finally, a general summary and perspective on construction strategies for next-generation 3D composite Li anode are presented.

Currently, there are a limited number of dynamic models available for braided composite plates with large overall motions, despite the incorporation of three-dimensional (3D) braided composites into rotating blade components. In this paper, a dynamic model of 3D 4-directional braided composite thin plates considering braiding directions is established. Based on Kirchhoff’s plate assumptions, the displacement variables of the plate are expressed. By incorporating the braiding directions into the constitutive equation of the braided composites, the dynamic model of the plate considering braiding directions is obtained. The effects of the speeds, braiding directions, and braided angles on the responses of the plate with fixed-axis rotation and translational motion, respectively, are investigated. This paper presents a dynamic theory for calculating the deformation of 3D braided composite structures undergoing both translational and rotational motions. It also provides a simulation method for investigating the dynamic behavior of non-isotropic material plates in various applications.

Numerical analysis based on micromechanics is an effective method to study the mechanical properties of three-dimensional (3D) braided composites, in which the establishment of micromechanics model is the basis of mechanical analysis. The direction cosine of fiber yarns and the characterization of geometric parameters of microstructure are two key issues in the modeling of microstructure. Focusing on these two key issues, the three-cell model of 3D four-directional braided composites are studied to comprehensively analyze various spatial directions of fiber yarns in the 45° division and horizontal division of unit cell, so as to obtain the detailed fiber yarn direction cosine. Aiming at the cross sections of three types of fiber yarns, the complex relationship between the braiding process parameters and the geometric parameters of the unit cell is analyzed and deduced. The unit cell structure is quantitatively characterized by using the braiding process parameters as the initial parameters, and the calculation methods of the volume fraction of fiber yarns and yarn filling coefficient are obtained. Finally, the predicted elastic constants by stiffness-volume averaging method are compared with experimental results, demonstrating the analysis results of fiber yarns directions. This paper can provide a theoretical reference for the microstructure modeling of 3D multi-directional braided composites, and has certain practical value in engineering.

Natural composites exhibit exceptional mechanical performance that often arises from complex fiber arrangements within continuous matrices. Inspired by these natural systems, we developed a rotational 3D printing method that enables spatially controlled orientation of short fibers in polymer matrices solely by varying the nozzle rotation speed relative to the printing speed. Using this method, we fabricated carbon fiber–epoxy composites composed of volume elements (voxels) with programmably defined fiber arrangements, including adjacent regions with orthogonally and helically oriented fibers that lead to nonuniform strain and failure as well as those with purely helical fiber orientations akin to natural composites that exhibit enhanced damage tolerance. Our approach broadens the design, microstructural complexity, and performance space for fiber-reinforced composites through site-specific optimization of their fiber orientation, strain, failure, and damage tolerance.

This work proposed a homogenized method to predict the modal properties of the three dimensional multi-axial hybrid composite. The multi-scale calculation process was characterized with a representative unit cell to derive the elastic parameters of the composite. Then the modal behaviors (natural frequency and modal shape) of the composite were simulated through the finite element method (FEM). The experimental modal analysis of key vibration parameters was conducted using a modal hammer with an acceleration sensor to verify the efficiency of the numerical results. The result shows that the maximum relative errors between experimental and FEM values of natural frequency are about 13%. Therefore, the numerical-experiment method could be used to predict the modal behavior of three dimensional multi-axial hybrids composite.