Effect of Fiber–Matrix Interface Friction on Compressive Strength of High-Modulus Carbon Composites

Carbon-fiber-reinforced polymers (CFRPs) enable lightweight, strong, and durable structures for many engineering applications including aerospace, automotive, biomedical, and others. High-modulus (HM) CFRPs enable the most significant improvement in mechanical stiffness at a lower weight, allowing for extremely lightweight aircraft structures. However, low fiber-direction compressive strength has been a major weakness of HM CFRPs, prohibiting their implementation in the primary structures. Microstructural tailoring may provide an innovative means for breaking through the fiber-direction compressive strength barrier. This has been implemented by hybridizing intermediate-modulus (IM) and HM carbon fibers in HM CFRP toughened with nanosilica particles. The new material solution almost doubles the compressive strength of the HM CFRPs, achieving that of the advanced IM CFRPs currently used in airframes and rotor components, but with a much higher axial modulus. The major focus of this work has been understanding the fiber–matrix interface properties governing the fiber-direction compressive strength improvement of the hybrid HM CFRPs. In particular, differences in the surface topology may cause much higher interface friction for IM carbon fibers compared to the HM fibers, which is responsible for the interface strength improvement. In situ Scanning Electron Microscopy (SEM)-based experiments were developed to measure interface friction. Such experiments reveal an approximately 48% higher maximum shear traction due to interface friction for IM carbon fibers compared to the HM fibers.