Engineering the electrospinning of MWCNTs/epoxy nanofiber scaffolds to enhance physical and mechanical properties of CFRPs

A cost-effective approach to improve the physical and mechanical properties of carbon fiber reinforced polymer (CFRP) prepreg composites, where electrospun multiwalled carbon nanotubes (MWCNTs)/epoxy nanofibers were synthesized and incorporated in between the layers of conventional CFRP prepreg composite has been presented. MWCNT-aligned epoxy nanofibers were successfully produced by an optimized electrospinning process. Nanofibers were deposited directly onto prepreg layers to achieve improved adhesion and interfacial bonding, leading to added strength and improvements in other mechanical properties. Thus, interlaminar shear strength (ILSS) and fatigue performance at high-stress regimes increased by 29% and 27%, respectively. Barely visible impact damage (BVID) energy increased significantly by up to 45%. The thermal and electrical conductivities were also enhanced significantly due to the presence of the highly conductive MWCNT networks between the CFRP layers. The presented method was capable of uniformly depositing high contents of MWCNTs at interlaminar ply interface of prepregs to strengthen/enhance CFRP properties, which has not been previously shown to be possible due to high resin viscosity caused by randomly oriented MWCNTs in epoxy system.