DOI: 10.25549/usctheses-c127-630561
title: Isothermal and hygrothermal agings of hybrid glass fiber/carbon fiber composite

description: New applications of fiber-reinforced polymer composites (FRPCs) are arising in non-traditional sectors of industry, such as civil infrastructure, automotive, and power distribution. For example, composites are being used in place of steel to support high-voltage overhead conductors. In this application, conductive strands of aluminum are wrapped around a solid composite rod comprised of unidirectional carbon and glass fibers in an epoxy matrix, which is commercially called ACCC conductor. Composite-core conductors such as these are expected to eventually replace conventional steel-reinforced conductors because of the reduced sag at high temperatures, lower weight, higher ampacity, and reduced line losses. ❧ Despite the considerable advantages in mechanical performance, long-term durability of composite conductors is a major concern, as overhead conductors are expected to retain properties (with minimal maintenance) over a service life that spans multiple decades. These concerns stem from the uncertain effects of long-term environmental exposure, which includes temperature, moisture, radiation, and aggressive chemicals, all of which can be exacerbated by cyclic loads. In general, the mechanical and physical properties of polymer composites are adversely affected by such environmental factors. Consequently, the ability to forecast changes in material properties as a function of environmental exposure, particularly bulk mechanical properties, which are affected by the integrity of fiber-matrix interfaces, is required to design for extended service lives. ❧ Polymer composites are susceptible to oxidative degradation at high temperatures approaching but not quite reaching the glass transition temperature (Tg). Although the fibers are stable at such temperatures, the matrix and especially the fiber-matrix interface can undergo degradation that affects the physical and mechanical properties of the structure over time. Therefore, as a first step, the thermal aging of an anhydride/epoxy network used in composite-reinforced conductor cables was investigated to determine the extent of thermal oxidative (surface effect) and non-oxidative (bulk effect) degradation. Thermal oxidation tests were performed in air-circulating and vacuum ovens at 180ºC and 200ºC (the maximum emergency temperature for ACCC conductors). The extent of oxidation during aging was determined by monitoring the thickness of the oxidized layer. Results showed that the oxidized layer thickness did not increase monotonically as a function of exposure time, and even decreased for a limited period of time. ❧ A phenomenological reaction-diffusion model was implemented to predict the thickness of oxidized layer, and the calculated results were compared with measurements for aging times up to 10,000 hours. The accuracy of the reaction-diffusion-based thickness values for the isothermally aged epoxy specimen was affected by the permeability properties of the oxidized material, and to a lesser extent by the degree of oxidation. The diffusivity varied because of changes in the density of the oxidized layer, the macro-void content, crack formation, and the molecular structures. To investigate the effects on diffusivity, the morphology of the oxidized layer and the void content was monitored over time.  In addition, the density of the oxidized specimens was calculated by direct measurements of volume and weight during exposure. An empirically based volume-loss model was developed to predict the changes in volume of the specimen as a function of aging times and hence to predict the effects on the oxidized layer thickness. Volume-loss measurements provide an indication of material degradation by demonstrating a direct measurement of shrinkage rates and insight into crack initiation, as opposed to typical weight-loss measurements that provide no insight into material failure. ❧ Thermal oxidation of a unidirectional carbon-fiber/glass-fiber hybrid composite was also investigated in this study. The aim was to determine oxidation kinetics, degradation mechanisms, oxidation thickness growth (a damage indicator), and oxidation effects on mechanical property. The epoxy composite rods were comprised of a carbon-fiber core and a glass-fiber shell. The thickness of the oxidized layer (TOL) was measured experimentally for samples exposed to 180ºC and 200ºC for up to 8,736 hours. A reaction-diffusion model was developed for each of the two hybrid sections to obtain the oxygen-concentration profile and the TOL within the composite rods. The TOL values measured experimentally were similar to the modeling predictions. The glass-fiber shell functioned as a protective layer, limiting the oxidation of the carbon-fiber core. ❧ The domain validity for the reaction-diffusion model was determined from gravimetric experiments by measuring the weight-loss of hybrid composite samples exposed isothermally in air and in vacuum at 200°C for up to 13,104 hours (1.5 years). The results showed that after prolonged thermal exposure, the degradation mechanism changed from thermal oxidation to thermal degradation. Thermogravimetric analysis (TGA) was performed to determine the thermal degradation and stability of the aged composite. The results indicated that the onset temperature of matrix degradation increased by increasing exposure time.   ❧ Inorganic fillers are widely used in pultruded parts to facilitate pultrusion, especially for long production runs. Therefore, another scope of this study was to investigate the effects of filler on oxidation kinetics and degradation mechanisms during thermal aging of pultruded composite rods. Similar aging tests and oxidation modeling to those for the unfilled composites were performed. The predicted and measured TOL values for filled composites were slightly less than those for unfilled composites. The addition of kaolin fillers did not affect the oxidation mechanism or the reaction rate of the epoxy matrix, although it did cause a slight decrease in the oxygen-transport properties (diffusivity and solubility of oxygen). ❧ The effect of thermal aging on mechanical properties of the aged composites was investigated. A relationship was derived relating TOL to tensile strength of the hybrid composite. The tensile strength remained essentially unchanged by thermal oxidation after 52 weeks of exposure. On the contrary, the oxidation resulted in a decrease in short-beam-shear (SBS) strength (a matrix-dominated property) due to degradation of matrix and fiber/matrix interface strength. However, the filled composites showed a lower reduction in SBS strength than that of the unfilled one for an identical duration of exposure. In addition, the effect of thermal aging on glass transition temperature (Tg) was determined for isothermal exposures at 180ºC and 200ºC. The simultaneous effects of post-curing and thermal degradation resulted in the change in Tg during exposure. ❧ Another study on the composite rod was performed to investigate the sorption kinetics and the effects of moisture on mechanical and physical properties. Sorption curves were obtained for both hybrid and non-hybrid composite rods to determine characteristic parameters, including the diffusion coefficient (D) and the maximum moisture uptake (M∞). The moisture uptake for the hybrid composites generally exhibited Fickian behavior (no hybridization effects), behaving much like non-hybrid composites. A two-dimensional diffusion model was employed to calculate moisture diffusivities in the longitudinal direction. Interfaces and thermally-induced residual stresses affected the moisture diffusion. In addition, the effect of hygrothermal aging on glass transition temperature (Tg), short beam shear strength (SBS), and tensile strength was determined for hygrothermal exposure at 60ºC and 85% relative humidity (RH). Property retention and reversibility of property degradation was also measured.  Microscopic inspection revealed no evidence of damage. ❧ Prediction of the lifetime of carbon-fiber/fiberglass (GF/CF) hybrid composites under various loads and service life conditions requires fundamental knowledge about the degradation mechanisms associated with overhead conductors with the hybrid GF/CF composite cores. This study provides adequate information on mechanical and thermal behaviors of the composite core under prolong isothermal and hygrothermal exposure, which is necessary for defining a lifetime model.