Toughening epoxy by nano-structured block copolymer to mitigate matrix microcracking of carbon fibre composites at cryogenic temperatures

The incorporation of rigid nanoparticles has proven to enhance microcracking resistance in carbon fibre reinforced polymer (CFRP) composites at cryogenic temperatures, enabling CFRP tanks to store cryogenic liquid like hydrogen without requiring liners. Herein, we investigate efficacy of low-modulus soft nanoparticles in addressing the microcracking challenges inherent in CFRP at cryogenic temperatures. By incorporating a tri-block copolymer (BCP) into an epoxy, nano-structured fillers with an average diameter of approximately 100 nm are formed. Experimental results reveal that, at a 2.5 wt% loading, the BCP significantly increase the fracture energy of the nanocomposite by 392% at −196 °C while maintaining stiffness and strength. More importantly, composite laminates made with the BCP-modified nanocomposite matrix can prevent microcracking carbon fibre composites, even they contain multiple plies with the same orientation, such as [04/904]s, which are known to be highly susceptible to matrix microcracking at cryogenic temperatures. An advanced high-fidelity micromechanical modelling revealed that the observed toughening effect of nanostructured block copolymer at cryogenic temperatures is attributed to the increased fracture resistance of the nanocomposite matrix. The findings of this research demonstrate that low loading of block copolymer can effectively mitigate the initiation and propagation of matrix microcracks at ultra-cold temperatures.