Processing-structure-property relationships of continuous carbon fiber polymer-matrix composites

This paper reviews the processing-structure-property relationships of continuous carbon fiber polymer-matrix composites, which are important for lightweight structures. Such relationships constitute the guiding principles in materials design, development and tailoring. Although much research has been performed for decades on the mechanical behavior of continuous fiber composites, the functional behavior (electrical, electromagnetic, dielectric, thermal, thermoelectric, vibration damping, etc.) of these materials are quite new, with research activities that are rapidly growing in recent years due to the importance of multifunctional structural materials and smart structures. In addition, the combined use of continuous fibers and nanofillers such as nanofibers and nanotubes is a relatively new direction that has provided hierarchical or multi-scale composites with attractive properties. The properties addressed in this review relate to the mechanical (static, dynamic, fatigue, wear), viscoelastic, thermal expansion, thermal conductivity, electrical, piezoresistive, dielectric, electromagnetic, thermoelectric and environmental durability behavior, as well as the effects of temperature, humidity, strain and damage. The structure/processing parameters relate to the fiber arrangement, interlaminar interface, curing pressure, fiber type, fiber treatments, fiber volume fraction, fillers, interlayers, coatings, through-thickness rods, polymer matrix and the fastening-relevant interface between contacting unbonded composites. In addition, this paper reviews the rapidly broadening applications of this class of materials.