Comparative Manufacturing of Hybrid Composites with Waste Graphite Fillers for UAVs

Materials of Unmanned Aerial Vehicles (UAVs) parts require specific techniques and processes to provide high standard quality, sufficiently strong, and lightweight materials. Composite materials with a proper technique have been considered to improve the performance of UAVs. Usually, the hybrid composite is developed by mechanical properties with the addition of the filler component (i.e., particle) in a matrix. This research work aims to develop the effective composite materials with better mechanical properties. Considering the manufacturing of hybrid composite materials, the vacuum process is an affecting factor on mechanical properties. The comparison of the hand lay-up process (HL) and vacuum infusion process (VI) with controlled pressure and temperature are studied in this research. In addition, graphite fillers (i.e., 5 wt%, 7.5 wt%, 10 wt%, and 12.5 wt%) are added to the studied matrix. Obviously, the ply orientation is one of the factors that affects mechanical properties. Moreover, two types of ply orientation (i.e., [0°/90°](4s) and [−45°/45°](4s)) are comprehensively investigated to improve mechanical properties in the three-point bending test. The experimental results show that the vacuum infusion process of ply orientation [0°/90°](4s) with the addition of 10 wt% graphite filler exhibits remarkable flexural strength from 404 MPa (without filler) to 529 MPa (10 wt% filler). Especially, the ply orientation of [0°/90°](4s) has higher flexural strength than [−45°/45°](4s) in both processes. Considering the failure, the fracture of the specimen propagates along the trajectory of fiber fabric orientation, leading to the breakage. Subsequently, the flexural strength under the vacuum infusion process is more significant than in the hand lay-up process. Effectively, it is found that the hybrid composite in this manufacturing has a higher strength-to-weight ratio to use in the structure of UAV instead of pure aluminum. It should be noted that the proposed hybrid composite strategy used in this study is not only limited to the UAV parts. The contribution can be extended to use in other applications such as automotive, structural building, and so on.