Development of sizing-free multi-functional carbon fibre nanocomposites

High quality multi-walled carbon nanotubes (CNTs) grown at high density using a low temperature growth method are used as an alternative material to polymer sizing and is utilised in a series of epoxy composites reinforced with carbon fibres to provide improved physical and electrical properties. We report improvements for sizing-sensitive mechanical and physical properties, such as the interfacial adhesion, shear properties and handling of the fibres, whilst retaining resin-infusion capability. Following fibre volume fraction normalisation, the carbon nanotube-modified carbon fibre composite offers improvements of 146% increase in Young's modulus; 20% increase in ultimate shear stress; 74% increase in shear chord modulus and an 83% improvement in the initial fracture toughness. The addition of CNTs imparts electrical functionalisation to the composite, enhancements in the surface direction are 400%, demonstrating a suitable route to sizing-free composites with enhanced mechanical and electrical functionality.