Development of three-dimensional woven weft interlock carbon-fiber-reinforced plastic composites and experimental investigation on their out-of-plane flexural performance

Abstract

Developing three-dimensional (3D) woven composites using various woven structures is important in the advanced composite research field. In this study, carbon-fiber 3D woven textile-reinforced epoxy–resin composites using four different woven structures (such as 2.5D, 3D-a, 3D-b, and 3D-c) were designed and fabricated based on a dobby-weaving loom, and vacuum-assisted resin transfer molding technology. In these 3D woven structures, part of weft insertions serves as binder yarns with a special weft interlock structural design, different weft-to-binder yarn ratios are obtained. Out-of-plane quasistatic three-point bending tests and dynamic low-velocity drop-weight impact tests were conducted on these woven composites to study the effect of woven structure on their flexural performance. Nondestructive ultrasonic C-scan and X-ray microcomputed tomography were applied to characterize the failure modes of the post impacted composites. We found that woven structures affect the flexural performance and failure mode of the developed composites, these structures with lower in-plane and binder yarn waviness exhibited higher quasistatic–flexural performance; 3D-c structure with serious in-plane yarn waviness combined with through-thickness binder yarn path exhibited superior impact resistance than other structures and survived more from composite through-thickness cracks and binder yarn breakage failures. Proper structural design is a key to improving flexural performance in specific engineering applications.