An integrated nanofiller spray and nanosecond pulse electrically-assisted method for synergistically interlaminar toughening and in-situ damage monitoring of CFRP composites

Nanomaterials have already been explored their potential for interlaminar toughening and crack-monitoring capabilities within the field of composite materials. However, efficient enhancement of interlaminar fracture toughness remains an unresolved challenge. Herein, a novel integrated filler spray and nanosecond pulsed electric field (nsPEF)-assisted curing technique is proposed for the fabrication of high-performance composite material system for the first time. The spraying technique proves to be an effective approach for depositing fillers, including carbon nanotubes (CNTs), graphene nanoplatelets (GNPs), and carbon nanofibers (CNFs), onto carbon fiber prepreg. Meanwhile, the nsPEF-assisted technique is utilized to enhance the wettability of resin to fiber, thus reducing void defects. The efficacy of this integrated technique is evidenced by the particularly low content of fillers (0.047 wt%). The experimental results show a substantial reduction of porosity in the composite by 49.36% (from 1.56% to 0.79%). Meanwhile, the mode I initiation and steady-state toughness of samples with CNTs and GNPs are remarkably improved by up to 47% and 82%, respectively, compared to the baseline. This represents the most significant improvement reported to date for non-functionalized CNTs and GNPs at such low concentrations. Moreover, the relative electrical resistance variation (Delta R/R-0%) of CNT/GNP sensors used for in-situ damage sensing increased by similar to 14%. This work pioneers the investigation of the synergistic effects of two promising techniques for preparing composite materials, offering advantages in terms of simplicity, multifunctionality, and the potential for industrial scalability.