Development of carbon fibre reinforced polymer matrix composites and optimization of the process parameters for railcar applications

Abstract The potential use of carbon fibre for railcar application stems from its excellent properties such as high strength to weight ratio and fire retarding abilities. This work studies the development of carbon fibre reinforced epoxy matrix composites and the optimization of the process parameters for railcar applications. Using the transfer moulding process, the composite comprising of mixture of double layers of polyacrylonitrile (PAN) based carbon fibre as reinforcement, epoxy resin which serves as the binder to form the matrix and silica additives were prepared and cured in a mould. The numerical experiment was performed using the Response Surface Methodology (RSM) and central composite design (CCD) comprising of two factors namely; the curing temperature (100–180 °C) and curing time (6–24 h). The statistical analysis of the numerical and physical experimentations were used to obtain a predictive model that correlates the tensile strength as a function of the curing temperature and curing time. There is a high degree of correlation between the results obtained from both the numerical and physical experimentations which implies that the developed model is suitable for predictive and correlative purposes. In addition, the results of the mechanical properties of the developed composite material indicate high tensile strength under varying loading conditions. This is an indication that the material possesses good strength and stiffness which makes the composite suitable for railcar applications. This work bring about the development of carbon fibre reinforced polymer and the determination of its mechanical properties for railcar applications.