Fabrication of GNPs sprayed carbon fiber and its effects on the interfacial and mechanical behavior of reinforced epoxy multiscale laminated composite

Abstract The current research compares the effects of modifying carbon fiber [via spraying graphene nanoplates (GNPs)] and/or GNPs reinforcement on the mechanical and interfacial behavior of carbon fiber epoxy composites. Using a spraying method, the epoxy matrix was reinforced, and carbon fiber was modified with 0.2 and 1 wt% of GNPs, respectively. Tensile, interlaminar, and dynamic mechanical analyses (DMA) tests were conducted on the composite to assess the role of GNPs in enhancing mechanical, interfacial, and thermomechanical properties. The obtained results indicate that the spraying technique effectively enhanced the ultimate tensile strength (UTS) and interlaminar fracture toughness (ILFT) of the composite. The UTS improved by 31%, while the ILFT significantly improved by 38%. Additionally, assessing the modulus gradient through the interface shows improved interfacial interaction between modified carbon fiber and reinforced epoxy. Scanning electron microscopy examination of the fractured surfaces indicated that the existence of nanofillers with high surface area contributed to significant improvements in adhesion between the modified fiber and reinforced epoxy matrix, leading to enhanced interfacial, mechanical, and thermomechanical properties of CFRPs for structural applications. Highlights Incorporation of surface modified carbon fibers and GNPs reinforcement in the epoxy matrix to enhance the interfacial interaction. Evaluation of the effects of GNP nanofiller on interfacial and mechanical performance of the composite. Fracture surfaces in ILSS, tensile, and mode I test were analyzed using FESEM. Utilization of nanoscale modulus mapping for the fiber‐matrix interface assessment.