In order to advance consistent lightweight construction principles in automotive and mechanical engineering, support frame construction made from high-performance materials is becoming more commonplace. These consist of complexly structured nodular connection elements. The required connection elements have not yet been produced satisfactorily. The developed node element structures in this paper are produced on a shuttle weaving loom by flattening and weaving them as multi-surface woven fabrics. The development of the woven concept for the realization of node element structures is based on the fragmentation of the individual sub-elements. The goal of this research is development of a flexible technology for weaving fabrics and intended for the integral realization of woven nodular semi-finished products with complex geometries and connections, which are to be used to connect Fiber-reinforced Plastic components in support frame structures.

Role of silane-treated stöber silica as reinforcing filler for nitrile rubber (NBR) has been studied. Stöber silica is synthesized by sol–gel method, and the surface of silica is modified with the treatment of silane-coupling agent viz. γ-mercaptopropyltrimethoxysilane (γ-MPS) in varying proportions. Average particle size of stöber silica of spherical shape in the range of 200 to 400 nm is evident from scanning electron microscopy (SEM). Surface modification of silica particle with silane-coupling agents decreases surface energy and reduces agglomeration of silica particles in rubber matrix. Stress–strain study and dynamic mechanical analysis of silica-filled composites are compared with the unfilled ones. Analysis of cross-linking density, mechanical properties, and storage moduli indicates a strong rubber–filler interaction in the silane-treated, silica-filled NBR composites. Silane treatment is found to be effective in uniform dispersion of silica in rubber matrix and in improving the mechanical properties of rubber composite. Different functionalities of organosilane at its both end improve the compatibility of silica with rubber matrix and offer better rubber–filler interaction.

A novel constitutive characterization method for uncured rubber behaviour has been developed in this article. A systematic measuring procedure was designed to fully investigate the uncured rubber complex stress–strain behaviour under different deformation patterns, which integrated three kinds of tests – the uniaxial tensile, the compression test and the shear test. It can be found from the observed behaviour that the uncured rubber has similar but much pronounced non-elastic stress–strain relationship, which is highly non-linear and highly rate dependent. A generalized Maxwell model with modified Yeoh model is developed to constitutively describe the observed phenomena in which parameters are identified by an evolution optimization scheme. Good agreement can be found between the model and the test data. Another finding is that, similar to vulcanized rubber, multi-test data are needed to obtain compatible constitutive models. The test results, findings and the developed model help rubber engineers deeply understand the uncured rubber’s mechanical behaviour and provide a base for rubber manufacturing simulation.

This work, conceived as a second step in the development of high-performance damping materials suitable for seismic application, describes the preparation and characterization of complex natural rubber-based composites containing hybrid nano- and conventional fillers. The cluster–cluster aggregation model was used to assess the apparent filler networking energy. The values obtained suggested that the presence of the hybrid nanofiller strengthens the filler networking. The same model was used to understand the mechanisms of energy dissipation. The damping coefficient was found to be in the sought range between 10% and 20% (at 0.5 Hz and high shear strain).

Drape simulation of textiles is a field of research, which is known in the clothing sector for a long time. The ongoing development of high-performance composites made of textile reinforcements and matrix materials focus the interests on a serial production in many industrial sectors, such as aviation and automotive industries. Challenges occur mainly in the serial production technologies and in supplying concepts for the preform architecture and shape. Research aims on the acceleration of preform manufacturing and the reduction of expensive pretests. Numerical simulation models can help to improve the composite development chain with structure and process simulation. A special challenge in drape modeling is the bending behavior of textiles. This study introduces a novel approach for modeling single textile layers as laminates to gain a correct mechanical behavior, where all deformation mechanisms are uncoupled. The implementation in the finite element software LS-DYNA® is described. An algorithm is introduced which provides the membrane stiffness for each layer of a laminate to fit the measured cantilever bending stiffness of textiles in every bending direction and bending side. The calculated parameters for the laminate formulation result in the requested bending stiffness for the textile layer. The cantilever bending stiffness can be used directly for dimensioning the model.

Woven barrier fabrics for filtration and operating room textiles feature permeable pore channels between yarn interlocking points (mesopores), which create an increased risk of penetration by contaminated fluids and particles. These pore channels can be reduced in size by high-density weaving. This, however, results in deteriorated drapability and performance characteristics. To meet the requirements made on the barrier effect without impairing the physiological properties of the textile, fluid-tight and particle-tight woven fabrics with adjustable porosity are being developed. This research aim could be realized by the targeted and partial application of microparticles into the mesopores. There, they form a meshed structure in the pores, whose size is thus reduced without them being entirely obstructed. The simultaneous retention of the micropores (pores between the individual filaments) in the woven fabric guarantees preservation of the physiological characteristics of the textile. The efficiency of the finishing was examined by an extensive physiological and physical characterization of the woven fabrics before and after particle application. Regarding the test method used to monitor the barrier effect and the channel paths, a test device was modified to simulate the demands of later, practical use.

Composites have now revolutionized most industries, like aerospace, marine, electrical, transportation, and have proved to be a worthy alternative to other traditional materials. However for a further comprehensive usage, the tailorability of hybrid composites according to the specific application needs on a large-scale production basis is required. In this regard, one of the major fundamental research fields here involves a technology development based on the multiaxial warp-knitting technique for the production of bionic-inspired and application-specific textile preforms that are force compliant and exhibit multi-material design. This article presents a newly developed yarn (warp) path manipulation unit for multiaxial warp-knitting machines that enables a targeted production of customized textile preforms with the above characteristics. The technological development cycle and their experimental validation to demonstrate the feasibility of new technology through production of some patterns for different field of applications are then discussed.

Polyethylene terephthalate multifilament fabrics used as filtration and operating room textiles possess through-thickness pore channels at the yarn intersections (mesopores). These pore channels pose a risk for the penetration of contaminated fluids and particles. The size of pore channels may be reduced by high-density weaving. However, this leads to reduced drapability and thus to degraded application properties of the fabric. To satisfy the requirements without impeding the physiological properties of the textile, fluid- and particle-tight fabrics are developed. This was realized by partial immobilization of functionalized micro particles into the meso-pores. A reduction of the pore size without complete pore-closure is achieved by establishing a net-like particle structure in the meso-pores. To match the requirements of intensive use, permanent particle-bonding to the fiber surface is necessary. This can be achieved by suitable polyethylene terephthalate fabric surface-modification, dependent on the particle functionalization. The investigations have shown that functionalized particles establish a very good inter particle bonding as well as to the fiber surface. An increased permanent bonding can be realized by a modification of the fabric surface which is tuned to the functionalization of the particle.

Fiber-reinforced composites are currently being used in a wide range of lightweight constructions. Function integration, in particular, offers possibilities to develop new, innovative products for a variety of applications. The large amount of experimental testing required to investigate these novel material combinations often hinders their use in industrial applications. This paper presents an approach that allows the layout of adaptive, fiber-reinforced composites by the use of numerical simulation. In order to model the adaptive characteristics of this functional composite with textile-integrated shape memory alloys, a thermo-elastic simulation is considered by using the Finite Element method. For the numerical simulation, the parameters of the raw materials are identified and used to generate the model. The results of this simulation are validated through deflection measurements with a specimen consisting of a glass fiber fabric with structurally integrated shape memory alloys and an elastomeric matrix system. The achieved experimental and numerical results demonstrate the promising potential of adaptive, fiber-reinforced composites with large deformation capabilities.

In this study we introduce an elastic composite, which has been manufactured using a fine carbonyl iron powder coated with a polymeric dielectric shell and dispersed in a silicone elastomer in a way as it is typically done manufacturing magnetorheological elastomers. Due to the used filler such a material possesses the capability of exhibiting magneto- and electrorheological effects. Our experiments have shown that the application of the magnetic field to the composite results in the magnetorheological effect, which becomes stronger in the case of the additional application of an electric field.