A literature review of up-to-date methods to strengthen Ti/carbon-fiber-reinforced polymer (CFRP) hybrid joints is given. However, there are little or no studies on Ti/CFRP joints by carbon fiber plug insert, which takes advantage of the extremely high surface adhesion area of ~6 μm CFs. Therefore, we cover the current status and review our previously published results developing hybrid joints by a CF plug insert with spot-welded Ti half-lengths to enhance the safety levels of aircraft fan blades. A thermoset Ti/CF/epoxy joint exhibited an ultimate tensile strength (UTS) of 283 MPa when calculated according to the rule of mixtures (RM) for the CF cross-section portion. With concern for the environment, thermoplastic polymers (TPs) allowed recyclability. However, a drawback is easy CF pull-out from difficult-to-adhere TPs due to insufficient contact sites. Therefore, research on a novel method of homogeneous low voltage electron beam irradiation (HLEBI) to activate a bare CF half-length prior to dipping in a TP resin was reviewed and showed that the UTS by the RM of Ti/EBCF/acrylonitrile butadiene styrene (ABS) and Ti/EBCF/polycarbonate (PC) joints increased 154% (from 55 to 140 MPa) and 829% (from 30 to 195 MPa), respectively, over the untreated sample. The optimum 0.30 MGy HLEBI prevented CF pull-out by apparently growing crystallites into the TP around the CF circumference, raising the UTS amount closer to that of epoxy.

Bird strike, volcanic rock, hailstones, micrometeoroids, or space debris can cause damage to aircraft and space vehicles, therefore their composite materials must have high impact resistance to maximize safety. In a 55% wt. CaCO₃ compression molded short glass fiber polyester GFRP-BMC (bulk molded compound), shortening the nominal 6.4 mm fiber length formulation, by 30 min extended mixing, to 0.44 mm was found to increase Charpy impact values, a_uc, without a change in the compression molding equipment. Specimens were cut from square panels in a spiral configuration in conformity with ASTM D 6110-02 for orthotropic panels, the flow direction approximately radially outward from the charge. At a median-fracture probability of P_f = 0.50, extended mixing improved a_uc by 29%, from 7.43 to 9.59 kJm⁻², and for each solidification texture angle, namely, 0 to 90 (random), 71, 45 and 18 deg, the a_uc increased by 25% (6.26 to 7.86 kJm⁻²), 18% (9.36 to 11.07 kJm⁻²), 35% (7.68 to 10.37 kJm⁻²), and 20% (6.96 to 8.36 kJm⁻²), respectively. This strengthening can be explained by an increased number of thermal compressive stress sites between the glass fiber and matrix due to a difference in the coefficient of thermal expansion (CTE) during cool-down, and shrinkage, with an increased number of spaces between fibers, |S_f| from 217 to approximately 2950 per mm³, enhancing impact energy.

Impact by hailstone, volcanic rock, bird strike, or also dropping tools can cause damage to aircraft materials. For maximum safety, the goal is to increase Charpy impact strength (a_uc) of a carbon-fiber-reinforced thermoplastic polyphenylene sulfide polymer (CFRTP-PPS) composite for potential application to commercial aircraft parts. The layup was three cross-weave CF plies alternating between four PPS plies, [PPS-CF-PPS-CF-PPS-CF-PPS], designated [PPS]₄[CF]₃. To strengthen, a new process for CFRP-PPS was employed applying homogeneous low voltage electron beam irradiation (HLEBI) to both sides of PPS plies prior to lamination assembly with untreated CF, followed by hot press under 4.0 MPa at 573 K for 8 min. Experimental results showed a 5 kGy HLEBI dose was at or near optimum, increasing a_uc at each accumulative probability, P_f. Optical microscopy of 5 kGy sample showed a reduction in main crack width with significantly reduced CF separation and pull-out; while, scanning electron microscopy (SEM) and electron dispersive X-ray (EDS) mapping showed PPS adhering to CF. Electron spin resonance (ESR) of a 5 kGy sample indicated lengthening of PPS chains as evidenced by a reduction in dangling bond peak. It Is assumed that 5 kGy HLEBI creates strong bonds at the interface while strengthening the PPS bulk. A model is proposed to illustrate the possible strengthening mechanism.

In an interlayered carbon fiber reinforced polycarbonate (CFRPC) composite constructed of nine CF plies alternating between ten PC sheets, designated [PC]₁₀[CF]₉, applying homogeneous low voltage electron beam irradiation (HLEBI) at 200 kV cathode potential, with V_c setting at a 43.2 kGy dose, to both finished sample surfaces resulted in a 47% increase in Charpy impact strength and a_uc at median fracture probability (P_f) of 0.50 over that of untreated, from 118 kJm⁻² to 173 kJm⁻². Increasingly higher V_c settings of 150, 175, and 200 kV successively increased a_uc at median-P_f of 0.50 to 128, 155, and 173 kJm⁻², respectively. Strengthening is attributed to increasing the HLEBI penetration depth, D_th, into the sample thickness. Since the [PC]₁₀[CF]₉ has an inhomogeneous structure, D_th is calculated for each ply successively into the thickness. Scanning electron microscopy (SEM) photos showed a hierarchy of fracture mechanisms from poor PC/CF adhesion in untreated; to sporadic PC adhesion with aggregated CF at 150 kV; to high consolidation of CFs by PC at 200 kV. X-ray photoelectron spectroscopy (XPS) examination of the CF surface in the fracture area showed C1s carbonate O–(C=O)–O and ester O–(C=O)–R peak generation at 289 to 292 eV to be non-existent in untreated; well-defined at 150 kV; and increased in intensity at 200 kV, after which a reduction was observed at 225 kV. Moreover, the 200 kV yielded the largest area sp³ peak at 49.5%, signifying an increase in graphitic edge planes in the CF, apparently as dangling bonds, for increased adhesion sites to PC. For O1s scan, 200 kV yielded the largest area O–(C=O)–O peak at 34%, indicating maximum PC adhesion to CF. At the higher 225 kV, increase in a_uc at P_f of 0.50 was less, to 149 kJm⁻², and XPS indicated a lower amount of O–(C=O)–O groups, apparently by excess bond severing by the higher V_c setting.

A new process of activating sizing film free (removed sizing) carbon fiber (SFF-CF) mats directly with electron beam irradiation (EBI) under oxygen-rich nitrogen gas prior to lamination assembly and hot-press was found to increase bending strength of CFRTP (CF reinforced thermoplastic polypropylene (PP)) interlayered composite composed of 3 SFF-CF mats between 4 PP sheets, [PP]₄[SFF-CF]₃. The hot-press fabrication was performed under 4.0 MPa at 473 K for 1 min. Experimental results showed optimal condition of 0.22 MGy-EBI under 2,000 ppm-O₂-rich, protective N₂ atmosphere improved bending strength, σ_b at all accumulative probabilities, P_f over that of untreated. This could be explained by maximum number of the strong covalent bonds of CF:C:C:PP and oxygen assisted CF:C:O:C:PP bonds adhering bare SFF-CF surface to PP, instead of the weak intermolecular bonding of CF(H₂O, N₂, O₂)PP of untreated. The optimal concentration of O₂ molecules together with the EBI probably purified the SFF-CF surface simultaneously generating dangling bonds, which already naturally exist in SFF-CF as evidenced by the highest intensity ESR peak whose inflection point was at B = 323 mT. This, along with attaching O groups to the SFF-CF surface can explain the increased SFF-CF to PP adhesion sites and bending strength increase. Fracture analysis showed the optimum condition prevented ply delamination and reduced damage area along sample length appearing to increase cohesion between the difficult to adhere thermoplastic PP and SFF-CF plies to take on higher loads. Although bending strength was increased, carefulness is always highly recommended when investigating unsized CF composites.