Controlling the wettability and adhesion of carbon fibers with polymer interfaces via grafted nanofibers

Interfacial properties in carbon fiber composites is one of the key parameters controlling their structural functionality. Here, we introduce a novel method to engineer carbon fiber-epoxy interfaces, via inclusion of nanofibers, towards higher interfacial strength and energy dissipation. In our method, thermally stabilized polyacrylonitrile (PAN) nanofibers are grafted onto carbon fibers via electro-spinning process, followed by nanofiber consolidation via solvent vapor and thermal treatment. These treatments partially dissolves nanofibers along the nanofiber-fiber interface and trigger entropic elasticity in nanofibers, thus, increasing the nanofiber-fiber interactions. The hybridization of carbon fibers with PAN nanofibers increased the interfacial shear strength (IFSS) by ∼48%, from 10.8 ± 2.6 to 15.9 ± 4.9 MPa. Postmortem fractography points to mechanical interlocking between nanofibers and epoxy and reinforcing effects of nanofibers in matrix as root causes of IFSS enhancement. As a result of adding nanofibers to carbon fiber, junction failure mode changes from a dominantly adhesive failure (at epoxy-fiber interface) to dominantly cohesive failure, and failure plane slightly shifts away from epoxy-fiber interface to within the epoxy. Compared to other types of whiskers grown on carbon fibers, such as CNTs, the method proposed here requires low temperatures (below 300 °C), during which no surface damages are expected to accumulate on carbon fibers.