Fabrication and Testing of Compression-Molded Carbon Fiber Reinforced Polymer (CFRP) Components

Abstract

Carbon fiber composites are widely used in aerospace, automotive, and energy sectors due to their high strength-to-weight ratio and durability, but their complex internal structures pose challenges for non-destructive testing and imaging. Effective radiographic evaluation is often hindered by the low X-ray attenuation of carbon fibers, necessitating the use of contrast agents to enhance visibility. This study investigates the impact of contrast agents on the mechanical and X-ray attenuation properties of carbon fiber composites. Test specimens were fabricated according to ISO 527-1B standards using compression molded carbon fiber infused with epoxy resin as well as cerium dioxide (CeO2) and barium sulfate (BaSO4) as contrast agents. High-resolution computed tomography (CT) scanning was utilized to evaluate the X-ray attenuation characteristics, while tensile strength testing was conducted to assess mechanical performance. The primary focus was to determine how contrast agents influence CT imaging visibility and detail, facilitating the detection and analysis of internal structures, alongside their effect on structural integrity. In addition, a representative part was fabricated to test how well this method works on a more complicated design. The results show that both CeO2 and BaSO4 significantly enhance X-ray contrast, with CeO2 providing superior visibility but causing a more pronounced reduction in tensile strength compared to BaSO4. Future work will focus on balancing contrast enhancement with mechanical performance by optimizing contrast agent type, concentration and distribution. This research contributes to an ongoing effort to enhance the efficacy of contrast agents in fiber-reinforced polymer matrices, aiming to optimize material properties for applications requiring advanced radiographic imaging and robust mechanical performance.

Date of Award	2025
Original language	English
Supervisor	Jonathan Glinz (Supervisor)