This paper presents the static mechanical behavior and the dynamic thermomechanical properties of four market-available reinforced and non-reinforced thermoplastics and photopolymer materials used as precursors in different additive manufacturing technologies. This article proposes a characterization approach to further address development of aeronautic secondary structures via 3D-printed composite materials replacing conventional manufactured carbon fiber reinforced polymer (CFRP) composites. Different 3D printing materials, technologies, printing directions, and parameters were investigated. Experimental results showed that carbon-reinforced ONYX_R material exhibits a transition point at 114 °C, a 600 MPa tensile strength, and an average tensile strain of 2.5%, comparable with conventional CFRP composites manufactured via autoclave, making it a suitable candidate for replacing CFRP composites, in the aim of taking advantage of 3D printing technologies. ONYX material exhibits higher stiffness than Acrylonitrile-Butadiene-Styrene Copolymer (ABS), or conventional Nylon 6/6 polyamide, the flexural modulus being 2.5 GPa; nevertheless, the 27 °C determined transition temperature limits its stability at higher temperature. Daylight High Tensile (further called HTS) resin exhibits a tensile strength and strain increase when shifting the printing direction from transversal to longitudinal, while no effect was observed in HighTemp DL400 resin (further called HTP).

The present investigation was conducted on the low-speed impact response of quasi-isotropic [±45/0/90°]_xs hybrid composite through laboratory level experimental tests. The purpose was to understand the behaviour that the different stacking sequences of hybrid glass/carbon fibre composites has on the ability of the material to sustain loads during low-speed impact events without developing critical structural failure in the material and improving the impact energy absorption properties, which is a relevant matter in aerospace and automotive industries. Drop-weight impact tests were carried out on two different laminates, with different stacking sequences, each of which were 16 symmetric inter-ply hybrid laminates named GC [+45G/−45C/0G/90C]₄s and, respectively, G-C [+45G/−45G/0G/90G/+45C/−45C/0C/90C]₂s, where G stands for glass fibre and C for carbon fibre. Both were comprised of epoxy matrix reinforced carbon/E-glass fibre woven fabric composites. The outcome of changing the hybrid stacking sequence, on the impact performances, was discussed. The damage morphologies and local failure mechanisms were analysed using visual inspection and a high-resolution laser scanner. Under 33 J impact energy, both tested hybrid composites exhibited approximately 10 kN peak load. Nevertheless, one key parameter, the time to peak load, significantly changed; the damage initiation threshold for GC samples occurred immediately before 6 kN, whereas for G-C samples this threshold appeared much earlier. This type of behaviour was partly connected to the delay in the propagation of delamination and fibre breakage, which was influenced by the high elastic energy absorption of the carbon fibres when compared with the glass fibres. The absorbed energy was higher for GC configuration, whereas a higher DI was observed for samples G-C indicating that a high percentage of the total energy was dissipated through the propagation of in-plane and out-of-plane fibre/matrix cracks. No perforation was observed on either configuration; nevertheless, the damage area significantly changed both in size and appearance from one configuration to another.

A 100 W fibre laser source was used to minimize the surface roughness of 3D-printed Onyx parts. Furthermore, this study aimed to determine the mechanism of surface finishing, the influence of the laser process parameters (laser power, pulse frequency, and laser scanning path) on the surface morphology, and the influence of the scanning path on the dimensional accuracy of the investigated Onyx 3D-printed specimens. A significant reduction in surface roughness of 91.15% was achieved on the S3 Onyx 3D-printed specimen following laser surface polishing treatment using a 50 W laser power and a frequency of 50 kHz. The laser scanning path had little influence on the surface roughness, but had a major impact on the geometrical deviation of the treated sample.

The present paper is focused on evaluating the most suitable dispersion method in the epoxy matrix of two self-healing systems containing dicyclopentadiene (DCPD) and 5-ethylidene-2-norbornene (ENB) monomers encapsulated in a urea-formaldehyde (UF) shell, prior to integration, fabrication and impact testing of specimens. Both microstructural analysis and three-point bending tests were performed to evaluate and assess the optimum dispersion method. It was found that ultrasonication damages the microcapsules of both healing systems, thus magnetic stirring was used for the dispersion of both healing systems in the epoxy matrix. Using magnetic dispersion, 5%, 7%, 10%, 12% and 15% volumes of microcapsules were embedded in glass fibre composites. Some of the samples were subjected to thermal cycling between −20 °C and +100 °C for 8 h, to evaluate the behaviour of both healing systems after temperature variation. Impact test results showed that the mechanical behaviour decreases with increasing microcapsule volume, while for specimens subjected to thermal cycling, the impact strength increases with microcapsule volume up to 10%, after which a severe drop in impact strength follows. Retesting after 48 h shows a major drop in mechanical properties in specimens containing 15% MUF-ENB microcapsules, up to total penetration of the specimen.

A new method for the synthesis and deposition of tungsten oxide nanopowders directly on the surface of a carbon-fiber-reinforced polymer composite (CFRP) is presented. The CFRP was chosen because this material has very good thermal and mechanical properties and chemical resistance. Also, CFRPs have low melting points and are transparent under ionized radiation. The synthesis is based on the direct interaction between high-power-density microwaves and metallic wires to generate a high-temperature plasma in an oxygen-containing atmosphere, which afterward condenses as metallic oxide nanoparticles on the CFRP. During microwave discharge, the value of the electronic temperature of the plasma, estimated from Boltzmann plots, reached up to 4 eV, and tungsten oxide crystals with a size between 5 nm and 100 nm were obtained. Transmission electron microscopy (TEM) analysis of the tungsten oxide nanoparticles showed they were single crystals without any extended defects. Scanning electron microscopy (SEM) analysis showed that the surface of the CFRP sample does not degrade during microwave plasma deposition. The X-ray attenuation of CFRP samples covered with tungsten oxide nanopowder layers of 2 µm and 21 µm thickness was measured. The X-ray attenuation analysis indicated that the thin film with 2 µm thickness attenuated 10% of the photon flux with 20 to 29 KeV of energy, while the sample with 21 µm thickness attenuated 60% of the photon flux.

This study focused on the thermal stability and ablative behavior assessment of five newly developed composite TPS configurations. All ten test samples were 3D printed via FDM using various fire-retardant thermoplastic materials, with and without reinforcement. Eight samples integrated a new thermal management internal air chamber conceptualized architecture. A prompt feasible approach for the flame resistance preliminary assessment of ablative TPS samples was developed, using an in-house oxy-acetylene torch test bench. Experimental OTB ablation tests involved exposing the front surface samples to direct flame at 1450 ± 50 °C at 100 mm distance. For each configuration, two samples were tested: one subjected to 30 s of flame exposure and the other to 60 s. During testing, internal temperatures were measured at two backside sample contact points. Recorded temperatures remained below 46 °C, significantly under the maximum allowable back face temperature of 180 °C set for TPSs. The highest mass losses were measured for PC and PETG FR materials, achieving around 19% (30 s) and, respectively, 36% (60 s), while the reinforced configurations showed overall only a third of this reduction. The study’s major outcomes were the internal air chamber concept validation and identifying two reinforced configurations as strong candidates for the further development of 3D-printed ablative TPSs.