MTA-BME Research Group

Development of multi-functional, high performance pseudo-ductile hybrid composites

Project ID:
OTKA FK131882
Supported by:
Nemzeti Kutatási, Fejlesztési és Innovációs Hivatal (NKFIH)
1 December 2019 - 30 November 2023
Supervisor (BME):
Dr. Gergely Czél
Participant researchers (BME):
Marino Salvatore Giacomo
Dr. Molnár Kolos
Dr. Pölöskei Kornél
Dr. Romhány Gábor
Dr. Szebényi Gábor
Dr. Toldy Andrea

Project summary

One of the biggest challenges for the 21st century’s transportation sector is to improve fuel economy and reduce carbon footprint in case of traditional internal combustion engine driven vehicles. Since the energy storage elements of electric vehicles constitute a significant additional load, weight reduction is a key challenge for both constructions, while structural stiffness and passenger safety is to be maintained. High strength, low density yet safely failing structural materials could enable the development of the next economic and environmentally friendly generation of vehicles. High performance carbon or glass fibre reinforced polymer matrix composites offer exceptional specific modulus and strength, but suffer from sudden and brittle failure, with no warning and insufficient residual load-bearing capacity. Pseudo-ductile composites provide a safe alternative to conventional ones showing a progressive failure character and improved failure strains, similar to those of metals. Another significant benefit is a clear sign of damage before final failure. The principal investigator of the programme demonstrated pseudo-ductility in thin-ply uni- and multidirectional hybrid composites under tension recently. One objective of the project is the further development of the pseudo-ductile composites primarily by the modification of the layer interfaces. The other direction of the research is to add valuable functions such as damage indication and repairability which are of significant interest for safe operation and reduced lifecycle cost.

Project results

Section 1
1 December 2019 - 30 November 2020
Design, manufacturing and structural testing of a pseudo-ductile sandwich panel with additional visual overload sensing feature were completed according to the work plan. A 600x300x10 mm size panel with carbon fibre/epoxy composite skins and foam core was fabricated with a full layer of glass/epoxy-carbon/epoxy hybrid composite visual overload sensor integrated into the bottom skin. This rather large size was selected to demonstrate that the recently patented sensing technology is suitable for high performance, industrial-scale components. The sensing layer provided clearly visible signs of overload in the form of light stripes when the high modulus carbon reinforced sensing layer started to fragment and delaminated locally around the fractures at a pre-defined strain. 40 mm long electronic strain gauges were applied successfully and provided accurate strain reading over the highly variable strain field after the triggering of the overload sensing layer. The trigger strain of the visual overload sensor was in line with the expected failure strain of the sensing layer. Acoustic emission damage monitoring was able to detect the triggering of the visual overload sensor and the obtained data correlated well with the knee point after the initial linear part of the load-displacement diagrams and the small drops in the load signal from the test machine indicating the fragmentation of the sensing layer.
Pseudo-ductile, self-monitoring sandwich panel

Section 2
1 December 2020 - 30 November 2021

Section 3
1 December 2021 - 30 November 2022

Section 4
1 December 2022 - 30 November 2023

Project-related publications

  1. Marino S. G., Czél G.: Improving the performance of pseudo-ductile hybrid composites by film-interleaving. Composites Part A (Applied Science and Manufacturing), 142, 106233/1-106233/16 (2021) IF=7.664 D1
  2. He H., Molnár K.: Fabrication of 3D printed nanocomposites with electrospun nanofiber interleaves. Additive Manufacturing, 46, 102030/1-102030/11 (2021) 10.1016/j.addma.2021.102030 IF=10.998 D1
  3. He H., Guo J., Illés B., Géczy A., Istók B., Hliva V., Török D., Kovács J. G., Harmati I., Molnár K.: Monitoring multi-respiratory indices via a smart nanofibrous mask filter based on a triboelectric nanogenerator. Nano Energy, 89, 106418/1-106418/ (2021) 10.1016/j.nanoen.2021.106418 IF=17.881 D1
  4. Kara Y., He H., Molnár K.: Shear‐aided high‐throughput electrospinning: A needleless method with enhanced jet formation. Journal of Applied Polymer Science, , e49104/1-e49104/13 (2020) 10.1002/app.49104 IF=3.125 Q2
  5. He H., Gao M., Török D., Molnár K.: Self-feeding electrospinning method based on the Weissenberg effect. Polymer, 190, 122247/1-122247/9 (2020) 10.1016/j.polymer.2020.122247 IF=4.43 Q1
  6. He H., Wang Y., Farkas B., Nagy Zs. K., Molnár K.: Analysis and prediction of the diameter and orientation of AC electrospun nanofibers by response surface methodology. Materials & Design, 194, 108902/1-108902/11 (2020) 10.1016/j.matdes.2020.108902 IF=7.991 Q1
  7. He H., Gao M., Illés B., Molnár K.: 3D Printed and Electrospun, Transparent, Hierarchical Polylactic Acid Mask Nanoporous Filter. International Journal of Bioprinting, 194, 108902/1-108902/11 (2020) 10.18063/ijb.v6i4.278 IF=6.638 Q1
  8. Wisnom M., Potter K., Czél G., Jalalvand M.: Strain overload sensor. GB2544792B, United Kingdom (2020)
  9. Marino S.G., Mayer F., Bismarck A., Czél G.: Effect of Plasma-Treatment of Interleaved Thermoplastic Films on Delamination in Interlayer Fibre Hybrid Composite Laminates. Polymers, 12, 2834/1-2834/24 (2020) IF=4.329 Q1

© 2014 BME Department of Polymer Engineering - Created by: Dr. Romhány Gábor