The Influence of Glass Fiber and Copper Wire z-Binder on the Mechanical Properties of 3D Woven Polymeric Composites

Three-dimensional composites (3D) have potential applications in various fields due to their enhanced properties compared to conventional two-dimensional composites (2D). This study investigates the effect of different volumes of z-binder made from copper wire and E-glass fiber on the mechanical properties of 3D woven polymeric composites. The tensile, flexural, and fracture toughness behavior of four types of 3D orthogonal woven composites were studied in addition to a comparative 2D composite. The creation of the 3D orthogonal single-ply fabrics involved weaving z-binders using two different copper wire diameters, single fiber bundles, and double fiber bundles, each combined with four layers of woven E-glass fiber. The consolidation process for both 2D fabric and single-fabric 3D woven composites was executed using the hand lay-up technique. The results showed that most 3D woven composites outperformed 2D composites in terms of fracture toughness (stress intensity factor KIC and energy release rate GIC) and flexural strain. However, a decrease in flexural strength and tensile properties was observed for all 3D composites. The specimen with a small copper diameter had the smallest decrease of 5% in tensile strength. Furthermore, a decrease of 9% and 21% was attained by reinforcing with double and single glass fiber bundle z-binders, respectively, as compared with 2D composites. The highest enhancement of 92.5% in flexural failure strain was attained with double glass fiber bundles of z-binder. The maximum improvement in KIC fracture toughness, reaching 126% and 101.5%, was observed in specimens with a single glass fiber bundle z-binder and those with a large copper wire diameter, respectively.