Preparation and characterization of carbon fiber spread tow needled preform and its composite based on novel short yarn needling method

Abstract Due to the high fiber volume fraction of carbon fiber spread tow plain weave fabrics, it is difficult for short fibers to be brought into the thickness direction to form needled fiber bundles during the needling process. The interlaminar performance of the carbon fiber spread tow needled preform is weak, and the in‐plane damage is also severe. Responding to this issue, this article proposed a new method for preparing carbon fiber spread tow needled preform based on short yarn needling, which was expected to manufacture high‐performance carbon fiber spread tow needled preform and composite. We conducted experimental research on the preparation and structural characterization of the preform, as well as the Mode I interlaminar mechanical properties and in‐plane tensile properties of composites. The results showed that the fiber volume fraction of the preform significantly increased, reaching to 55.7%–56.1%, which was 25.5%–25.9% higher than that of traditional needled preform. The Mode I interlaminar property of carbon fiber spread tow needled composite reached to 905–4376 J m −2 , which was improved by 29.3%–525.1% and 125.8%–1054.6% compared to traditional needled composite and laminated composite, respectively. At the same time, the tensile strength and tensile modulus were also improved by 191.5%–212.2% and 66.2%–78.1% compared to traditional needled composites. The preparation method of carbon fiber spread tow needled preform based on short yarn needling has laid the foundation for the 3D printing molding of dry fiber fabrics and is expected to be applied to high‐quality needling of high thickness and large curvature‐shaped fabric preforms. Highlights A novel method was proposed for preparing high‐performance carbon fiber spread tow needled preform based on short yarn needling. The fiber volume fraction of novel carbon fiber spread tow needled preform significantly increased, reaching to 55.7%–56.1%. The G Ic of the novel carbon fiber spread tow needled composite was improved by 29.3%–525.1% compared to the traditional needled composite. The tensile strength and tensile modulus were also improved by 191.5%–212.2% and 66.2%–78.1%, compared to traditional needled composites.