Constructing a Superior Interfacial Microstructure on Carbon Fiber for High Interfacial and Mechanical Properties of Epoxy Composites

The interface quality is crucial for the properties of carbon fiber-reinforced polymer- matrix composites (CFRPs). In order to improve the interfacial and mechanical properties of CFRPs, a superior gradient modulus interfacial microstructure is constructed on the carbon fiber (CF) surface by chemically grafting a self-assembly carboxyl-terminated hyperbranched polymer (HP-COOH). A monofilament debonding test, a short beam shear test, an impact test and a dynamic mechanical thermal analysis (DMTA) were conducted to investigate the properties of the modified composite. Prominent improvements of 79.6% for the interfacial shear strength, 51.5% for the interlaminar shear strength, and 49.2% for the impact strength, as well as superior heat-resistance properties are achieved for composites with the gradient modulus interface over those of the untreated CF composites. The mechanism for performance improvement is mainly attributed to the enhanced CF surface energy, mechanical interlocking, and chemical bonding interactions. In particular, an atomic force microscopy (AFM) test proved that the gradient modulus interfacial microstructure formed by HP–COOH could widen the interface layer thickness and buffer the sharp variations in the modulus from CF to resin, thereby transmitting an external force and reducing the stress concentration. This work provides a facile and efficient strategy for constructing a superior and versatile interface for high- performance composites.