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Mechanical performance of epoxy/carbon fiber laminated composites

Article  in  Journal of Reinforced Plastics and Composites · March 2014

DOI: 10.1177/0731684413518255

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Original Article
Journal of Reinforced Plastics
and Composites

Mechanical performance of epoxy/carbon 2014, Vol. 33(8) 733–740

! The Author(s) 2014
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DOI: 10.1177/0731684413518255
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Hossein Rahmani, S. Heydar Mahmoudi Najafi and

Alireza Ashori

Abstract
The objective of this research work was to gain a better understanding of the mechanical properties of epoxy resin
composites reinforced with carbon fiber. For this purpose, the effects of fiber orientations, resin types, and number of
laminates on mechanical properties of laminated composites have been investigated. In the sample preparation, com-
posites were manufactured by hand lay-up process, using a fiber-to-resin ratio of 40:60 (w:w). To investigate the effect of
fiber orientation, angles of 0 , 35 , 45 , and 90 were selected. Results show that the mechanical properties, in terms
of tensile, flexural and impact strengths, were mainly dependent on the fiber orientations followed by the number of
laminates. At a similar fiber orientation, the composites made with EM500 epoxy resin showed the highest mechanical
properties (such as tensile and flexural and impact strengths) compared to other evaluated composites. However, the
differences were not highly significant. The results indicated that the mechanical properties of composites made with five-
ply were generally slightly greater than three-ply composites. It may be due to the bondline defects, which adversely
influence the mechanical properties. Scanning micrographs of the composites showed that the epoxy matrix material was
fully adhered to the fibers, indicating a strong interface. It can be concluded that the order of increment parameters in
the mechanical properties of the composites is fiber orientation > number of laminates > resin type. In addition, the
tensile and flexural properties were superior in case of 35 fiber orientations.

Keywords
Laminated composites, fiber orientation, epoxy resin, carbon fiber, mechanical properties

Introduction
packaging, coating, electronics, automotive, and aero-
Epoxy resin has been of significant importance to the space industries.5,6 They have high strength-to-weight
engineering community for many years. Components and stiffness-to-weight ratios. These composites have
made of epoxy-based materials have provided out- unique advantages over monolithic materials, such as
standing mechanical, thermal, and electrical proper- high strength, high stiffness, long fatigue life, low dens-
ties.1 Using an additional phase (e.g. inorganic fillers) ity, corrosion resistance, wear resistance, and environ-
to improve the properties of epoxy resins has become a mental stability.7 Laminated composites are susceptible
common practice.2 It has been established in recent to mechanical damages when they are subjected to
years that the polymer-based composites reinforced efforts of tension, flexural, and impact, which can
with carbon fiber can significantly improve the mech-
anical, thermal, and barrier properties of the pure poly-
mer matrix.3 Moreover, these improvements are Department of Chemical Technologies, Iranian Research Organization for
achieved through conventional processing techniques Science and Technology (IROST), Tehran, Iran.
without any detrimental effects on processability,
appearance, density, and ageing performance of the Corresponding author:
A Ashori, Department of Chemical Technologies, Iranian Research
polymer matrix.4 Due to the above characteristics, the Organization for Science and Technology (IROST), P.O. Box 15815-
laminated fiber-reinforced composite materials such as 3538, Tehran, Iran.
epoxy/carbon fiber composites are widely applied in Email: ashori@irost.org

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734 Journal of Reinforced Plastics and Composites 33(8)

lead to material failure. Therefore, it is necessary to use composite panels with thicknesses of 0.4 and 0.7 mm
materials with improved mechanical properties.8 (each ply was approximately 0.135 mm thick) were fab-
Mechanical properties of epoxy polymeric compos- ricated, respectively. To investigate the effect of fiber
ites can be enhanced through the improvement of the orientation, angles of 0 , 35 , 45 , and 90 were selected
interlaminar properties by toughening resin matrix9,10 in this study. The ratio of epoxy to carbon fiber was
and fiber reinforcement.8,11 Rahmani et al.12 investi- 60:40 by weight for all experiments. Before hand lay-
gated the influence of fiber orientation, fiber content, up, the mold was coated with a releasing agent to
and number of plies on mechanical prosperities. When ensure that the fibers will not adhere to the mold. The
composite materials are designed, the reinforcements stacking sequences, formulations, and abbreviation
are always oriented in the load direction. However, if used for the respective composites prepared are given
the load direction is variable and not parallel to the in Table 3. A brush was used to impregnate the fibers
fibers, it becomes more important to investigate with the resin evenly. The next fabrication process was
the laminate mechanical behavior.13 The main aim of vacuum bagging. The specimen was placed in a plastic
the present investigation was to study the influence of vacuum bag and sealed to isolate it from the atmos-
resin type, fiber orientations, and number of laminates phere. The sample was compacted by vacuum, and
on the mechanical properties. For parametric study, the breather cloth collected the excess resin and
mechanical properties in terms of tensile, flexural, and removed the air bubbles and volatiles. Finally, the spe-
impact strengths as well as morphological characteris- cimen was placed in an autoclave at 60 C for 12 h.
tics of the composite samples were evaluated.
Testing procedures
Experimental The specimens were tested following ASTM standard
D-638 for tensile properties, D-790 for flexural proper-
Materials ties, and D-256 for impact strength. The specimens
Fiber. Unidirectional carbon fiber, Toray’s Torayca were water-jet cut from the panels parallel to the x-
T700S-12 k, was employed to lay-up composite lamin- axial direction (based on the first layer). Tensile and
ates as reinforcing agent. Table 1 presents mechanical bending tests were conducted using a Universal
and physical properties of the used fibers. Testing Machine (Santam model STM-150), with a
constant crosshead speed of 5 mm/min. An extensom-
Matrix. Three different types of resin materials were eter, with an 80-mm gauge length, was used to measure
used in this study: Araldit LY 5052, Lionbond the displacement of the specimens. Izod impact test was
EM500, Epon 828. Table 2 shows some characteristics performed with a pendulum apparatus (CEAST model
of the used resin types along with their hardeners. 6958) using conventional V-notched specimens. Due to
the flexibility, the impact samples needed a cryogenic
Releasing agent. Mould release agent of QZ 13 was a temperature treatment using liquid nitrogen.
product of Huntsman Petrochemical Co. The mold Consequently, the specimens were conditioned in a
was coated with releasing agent to ensure that the chamber for 15 min before testing. The temperature of
fibers will not adhere to the mold. chamber was set at –70 C. Three replicate tests were
conducted for each treatment.
Preparation of composites
The details of the composites preparation have been
Morphological characterization
reported elsewhere.12 In short, three- and five-ply Studies on the morphology of the composites were car-
ried out using scanning electron microscopy (SEM).
Micrographs of the surfaces of tensile fractured speci-
Table 1. Mechanical and physical properties of the used mens were taken using SEM TESCAN (model WEGA-
carbon fiber. II). Specimens were sputter-coated with gold to a
thickness of 20 nm in order to prevent electrical char-
Property Value Standard
ging during the examination. An accelerating voltage of
Tensile strength (MPa) 2550 TY-030B-01 15 kV was used to collect the SEM images.
Tensile modulus (GPa) 135 TY-030B-01
Elongation (%) 2.1 TY-030B-01 Results and discussion
Density (g/cm3) 180 TY-030B-02
The average tensile, flexural, and impact properties
Carbon content (%) 93
determined for all of the composite materials are

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Rahmani et al. 735

shown in Table 4. Overall trend shows that fiber orien- the composite formulations, the tensile modulus did
tation had the most significant influence on the not show a considerable increase.
improvement of mechanical properties. For easier com- As it can be seen from Figure 1(c), the elongation at
parison, the mechanical properties of the produced break of specimens increased moderately with increas-
composites are shown in Figures 1–3. ing the number of laminates. Results indicate that there
is a moderate increase in the values of elongation at
break by increasing the number of laminates, and
Tensile properties there are significant differences among the resin types
Figure 1(a–c) illustrates tensile properties in terms of
strength, modulus, and elongation at break for the vari-
ous fabricated composites, respectively. The tensile
strengths of the composites slightly varied with resin Table 3. Compositions of the epoxy/carbon fiber laminated
type; however, differences were not highly significant composites.
(Figure 1(a)). The tensile strength increased from an Sample Resin Number Fiber
average of 20 MPa for LY3/3 and EP3/3 samples to code type of laminate orientation ( )
an average of 1059 MPa for LY5/4 composite. As it
can be seen, the highest and the lowest tensile strengths LY3/1 LY 5052 3 0, 90, 0
were found for the five-ply composites. In other words, LY3/2 LY 5052 3 0, 35, 0
the tensile strength does not seem to be affected by the LY3/3 LY 5052 3 90, 45, 90
number of laminates, while on changing the fiber orien- LY5/4 LY 5052 5 0, –35, 0, +35, 0
tation, the tensile strength tends to decrease or increase LY5/5 LY 5052 5 +35, –35, 0, +35, –35
considerably. It is to be noted that higher load was LY5/6 LY 5052 5 +35, –35, 0, –35, +35
required for fracture of laminates in the case of  35 LY5/7 LY 5052 5 0, 90, 0, 90, 0
orientations. In other words, the composites with 0 , EM3/1 EM 500 3 0, 90, 0
35 , 0 and 0 , –35 , 0 , +35 , 0 orientations showed EM3/2 EM 500 3 0, 35, 0
the highest tensile strengths and moduli among the stu- EM3/3 EM 500 3 90, 45, 90
died composites. It can be concluded that the dominant
EM5/4 EM 500 5 0, –35, 0, +35, 0
factor is the fiber orientation.
EM5/5 EM 500 5 +35, –35, 0, +35, –35
The trend of tensile moduli of the composites was
similar to that of tensile strength discussed earlier EM5/6 EM 500 5 +35, –35, 0, –35, +35
(Figure 1(b)). The tensile moduli of the composites EM5/7 EM 500 5 0, 90, 0, 90, 0
vary significantly with fiber orientations. The composite EP3/1 EPON 828 3 0, 90, 0
type LY5/4 (using 0 , –35 , 0 , +35 , 0 ) showed the EP3/2 EPON 828 3 0, 35, 0
highest tensile modulus compared to other studied EP3/3 EPON 828 3 90, 45, 90
composites, whereas composites types LY3/3, EM3/3, EP5/4 EPON 828 5 0, –35, 0, +35, 0
and EP3/3 exhibited the lowest tensile moduli. Resin EP5/5 EPON 828 5 +35, –35, 0, +35, –35
type and number of laminates did not have strong influ- EP5/6 EPON 828 5 +35, –35, 0, –35, +35
ence on the mechanical properties of composites. In EP5/7 EPON 828 5 0, 90, 0, 90, 0
addition, with increasing the number of laminates in

Table 2. Physical properties of the used resins and hardeners.

Properties LY 5052 Aradur 5052 EM 500 H 917 EPON 828 TETA 3234

Appearance Clear liquid Clear liquid Clear liquid Amber liquid Clear liquid Clear liquid
Color (Gardner) 2 4 – – 1 Max. 200
Viscosity at 25 C 1000–1500 cps 40–60 cps 1000–1500 cps 60 cps 1100–1500 cps 25 cps
Density at 25 C 1.17 g/cm3 0.94 g/cm3 1.16 g/cm3 0.96 g/cm3 1.16 g/cm3 0.98 g/cm3
Flash point 140 C 93 C – – 249 C 275 C
Mix ratio (by weight) 100 38 100 25 100 15
Equivalent weight (g/eq.) 146–150 – 180–190 – 185–192 –
Supplier Huntsman Huntsman Lionbond Lionbond Momentive Momentive

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736 Journal of Reinforced Plastics and Composites 33(8)

Table 4. Mechanical properties of various laminated compositesa.

Sample Tensile Tensile Elongation Flexural Flexural Impact

code strength (MPa) modulus (GPa) at break (%) strength (MPa) modulus (GPa) strength (J/m)

LY3/1 329 (56) 27.5 (2.6) 1.04 (0.20) 525 (87) 28.5 (1.1) 2/1 (0.4)
LY3/2 1017 (82) 73.4 (4.8) 1.25 (0.15) 1110 (103) 51.9 (2.4) 2.2 (0.7)
LY3/3 20 (2) 6.8 (0.5) 0.29 (0.05) 140 (94) 4.1 (2.8) 2.8 (0.3)
LY5/4 1059 (90) 80.0 (3.1) 1.33 (0.11) 996 (107) 48.0 (1.3) 5.5 (0.4)
LY5/5 518 (44) 45.7 (5.9) 1.49 (0.12) 535 (84) 22.6 (3.1) 4.5 (1.05)
LY5/6 544 (64) 46.7 (4.3) 1.71 (0.16) 118 (62) 23.6 (1.4) 6.8 (0.2)
LY5/7 1058 (23) 59.0 (2.8) 1.63 (0.03) 769 (61) 40.4 (1.7) 5.2 (0.2)
EM3/1 1043.8 (71.9) 60.66 (4.69) 1.63(0.11) 1265.7 (90.6) 51.32 (2.48) 3.25 (0.8)
EM3/2 879 (56) 56.12 (8.15) 0.55 (0.11) 1029.45 (54.4) 46.08 (2.97) 3.01 (0.8)
EM3/3 21.4 (0.4) 6.3 (0.35) 0.34 (0.02) 85.4 (19.8) 2.45 (1.17) 10.8 (0.8)
EM5/4 879.5 (81.8) 61.57 (6.57) 1.48 (0.13) 822.55 (29.6) 47.05 (1.76) 10.23 (0.9)
EM5/5 487.9 (36.9) 47.19 (7.14) 1.55 (0.133) 796.1 (113.3) 30.22 (1.93) 11.02 (0.9)
EM5/6 532.53 (35.6) 34.61 (1.95) 1.79 (0.127) 554.4 (69.6) 26.09 (1.6) 7.42 (1)
EM5/7 526.8 (72) 51.7 (4.11) 0.94 (0.05) 1080.35 (33.9) 54.29 (1.07) 7.68 (0.8)
EP3/1 915.7 (49.7) 59.2 (2.52) 1.43 (0.11) 1008.97 (51.7) 55.47 (3.11) 2.3 (0.3)
EP3/2 758.37 (105.8) 70.84 (6.76) 1.12 (0.04) 1055.6 (82) 54.24 (2.1) 2.44 (0.2)
EP3/3 20.3 (1.2) 6.92 (0.42) 0.46 (0.15) 79.3 (82) 2.23 (0.6) 1.51 (0.2)
EP5/4 647.3 (54.6) 71.58 (2.09) 0.95 (0.09) 911.97 (52) 57.57 (2.58) 5.33 (0.6)
EP5/5 393.4 (55.3) 35 (8.25) 1.36 (0.153) 495 (90.1) 21.87 (3.7) 4.77 (0.5)
EP5/6 411.1 (24.8) 33.51 (1.95) 1.49 (0.04) 640.95 (82.1) 28.02 (2.13) 8.13 (0.7)
EP5/7 977.07 (81.7) 65.71 (5.73) 1.52 (0.12) 993.05 (62) 46.56 (2.46) 6.23 (1.1)
a
Numbers in the parentheses are standard deviations.

and the fiber orientations. Resin type LY showed the composites including the fiber orientations, fiber-
highest elongation at break and composite types LY5/6 matrix adhesion, stress transfer at the interface, and
and EM5/6 showed the most flexible behavior, with mixing temperatures. One of the most important par-
1.8% and 1.7%, respectively. This result is mainly ameters controlling the mechanical properties of long
explained by fiber orientation. In other words, more fibers composite is the fiber orientation.13
elongation was observed in 35 orientations. The Comparison of the results for three different resin
elongation is minimal in case of 90 orientation. types shows that the flexural strengths and moduli of
the composites made with five-ply were generally higher
than three-ply composites. It is also noteworthy that
Flexural properties with increasing the number of laminates, the bondline
Figure 2(a and b) shows the results of flexural strength defects, e.g. voids, kissing bonds and porosity are
and modulus of composites as function of treatment increased, which may adversely influence the structural
condition, respectively. The composite type EM3/1 performance of the bonded joints.14
shows the highest flexural strength, whereas composites
types LY3/3, EM3/3, and EP3/3 exhibited the lowest
strengths and moduli. Maximum flexural tensile was
Izod impact strength
1266 MPa for EM3/1 composite, while the maximum Figure 3 shows the Izod notched impact strengths of
modulus of EP5/4 was approximately 57.6 GPa. In the composites. The impact properties of the compos-
other words, the maximum and minimum flexural ites varied considerably with fiber orientations and
moduli were in case of 35 and 90 orientations, number of laminates. At a certain number of laminates,
respectively. This kind of behavior may be explained the different impact strengths among the manufactured
by the improved interfacial adhesion between the composites can be attributed to the role of fiber orien-
matrix and fibers. In addition, various parameters influ- tations. From Figure 3 it is evident that fiber orienta-
ence the flexural properties of fiber-reinforced tions of the composites showed the most influence on

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Rahmani et al. 737

1190
(a)
1020

Tensile strength (MPa)

850

680

510

340

170

0
LY3/1
LY3/2
LY3/3
LY5/4
LY5/5
LY5/6
LY5/7

EM3/1
EM3/2
EM3/3
EM5/4
EM5/5
EM5/6
EM5/7

EP3/1
EP3/2
EP3/3
EP5/4
EP5/5
EP5/6
EP5/7
84
(b)
72
Tensile modulus (GPa)

60

48

36

24

12

0
LY3/1
LY3/2
LY3/3
LY5/4
LY5/5
LY5/6
LY5/7

EM3/1
EM3/2
EM3/3
EM5/4
EM5/5
EM5/6
EM5/7

EP3/1
EP3/2
EP3/3
EP5/4
EP5/5
EP5/6
EP5/7
2.1
(c)
1.8
Elongation at break (%)

1.5

1.2

0.9

0.6

0.3

0.0
LY3/1
LY3/2
LY3/3
LY5/4
LY5/5
LY5/6
LY5/7

EM3/1
EM3/2
EM3/3
EM5/4
EM5/5
EM5/6
EM5/7

EP3/1
EP3/2
EP3/3
EP5/4
EP5/5
EP5/6
EP5/7

Sample code

Figure 1. Comparison of tensile strengths (a), tensile moduli (b), and elongation at break (c) of the epoxy/carbon fiber laminated
composites.

the impact strength. Among various formulations, our previous report on carbon fiber/epoxy compos-
composite type EM5/4 had the highest improvement ites.12 Like flexural and tensile properties, resin type
in impact strength, whereas composite EP3/3 fabricated did not show significant effect on the impact strength.
with fiber orientations of 90 , 45 , 90 exhibited the Regardless of resin type, composites made with five-ply
lowest impact strength. This result is consistent with exhibited the highest impact strength; whereas three-ply

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738 Journal of Reinforced Plastics and Composites 33(8)

1400
(a)
1200

Flexural strength (MPa) 1000

800

600

400

200

0
LY3/1
LY3/2
LY3/3
LY5/4
LY5/5
LY5/6
LY5/7

EM3/1
EM3/2
EM3/3
EM5/4
EM5/5
EM5/6
EM5/7

EP3/1
EP3/2
EP3/3
EP5/4
EP5/5
EP5/6
EP5/7
70
(b)
60
Flexural modulus (GPa)

50

40

30

20

10

0
LY3/1
LY3/2
LY3/3
LY5/4
LY5/5
LY5/6
LY5/7

EM3/1
EM3/2
EM3/3
EM5/4
EM5/5
EM5/6
EM5/7

EP3/1
EP3/2
EP3/3
EP5/4
EP5/5
EP5/6
EP5/7
Sample code

Figure 2. Comparison of flexural strengths (a) and moduli (b) of the epoxy/carbon fiber laminated composites.

14
Izod impact strength (J/m)

12

10

0
LY3/1
LY3/2
LY3/3
LY5/4
LY5/5
LY5/6
LY5/7

EM3/1
EM3/2
EM3/3
EM5/4
EM5/5
EM5/6
EM5/7

EP3/1
EP3/2
EP3/3
EP5/4
EP5/5
EP5/6
EP5/7

Sample code

Figure 3. Izod impact strengths of the epoxy/carbon fiber laminated composites.

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Rahmani et al. 739

Figure 4. SEM micrographs of tensile fracture surfaces of the composite types of LY5/4 (a and d), EM5/4 (b and e), and EP5/4
(c and f).

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 740 Journal of Reinforced Plastics and Composites 33(8)

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