FABRICATION AND MECHANICAL PROPERTIES OF POLYMER MATRIX COMPOSITES WITH HYBRID CERAMIC-METAL REINFORCEMENT

Abstract

Polymer Matrix Composites (PMCs) enjoy extensive application across various industrial fields, courtesy of their exceptional overall mechanical and functional performances, as well as their cost-effective and environmentally friendly manufacturing process. Metal reinforcements are instrumental in augmenting architectural liberty and functional aptitudes of PMCs, at low costs. However, their application is hindered by weak interfacial bonding. In this doctoral study, Plasma Electrolytic Oxidation (PEO) technique was explored, with a specific focus on process optimisation for application on thin fibre substrates, to create gamma-Al2O3/Al fibres, which were further utilised for reinforcing epoxy resin. Investigating the tensile characteristics of the gamma-Al2O3/Al fibre and its adhesion with epoxy resin formed a part of this study, along with an evaluation of the flexural and compression behaviour of the epoxy composite reinforced with gamma-Al2O3/Al fibres. In-depth failure analysis was conducted using a variety of methods including Scanning Electron Microscopy (SEM), Digital Image Correlation (DIC) and in-situ X-ray Computed Tomography (XCT). The results demonstrate the benefits of a PEO-based approach in the preparation of hybrid ceramic-metal reinforcements for polymer matrix composites with enhanced mechanical properties. Although the PEO process decreased the tensile properties of Al fibres, the resulting composites still exhibited improved mechanical performances. This is primarily due to the superior interfacial adhesion at the fibre and epoxy interface facilitated by the gamma-Al2O3 oxide coating. The failure mechanism of the fibre embedded in the composite is directly subjected to the thickness of the oxide coating. Additionally, gamma-Al2O3/Al fibres with a lower oxide ratio exhibit further benefits, especially in the context of composite production for mechanical engineering applications.

Date of Award	1 Aug 2024
Original language	English
Awarding Institution	The University of Manchester
Supervisor	Aleksey Yerokhin (Supervisor) & Akin Atas (Supervisor)