Influence of the Nanostitch Sensor Embedment on the Fibrous Microstructure of Glass Fiber Prepreg Laminates

Changes in the fibrous microstructure in glass fiber/epoxy prepreg quasi-isotropic laminates after the introduction of embedded sensors in the form of “nanostitch” as interleaves are investigated using 3D imaging with synchrotron radiation computer tomography (SRCT). Nanostitch interfaces are created by aligned carbon nanotubes (CNTs) with two different morphologies. The laminates are fabricated using an autoclave. The investigated microstructural features include: thickness variability of the plies and laminate, resin rich gaps at the interfaces, presence of voids, and misorientation of plies and misalignment of fibers deep inside the plies and close to the ply interfaces. The analysis of the SRCT images, at a resolution of 0.65 µm, shows the following: (1) the laminate preserves its thickness, with a resin/CNT-rich gap of ~5 µm created at the interface and the plies compacted by nano-capillarity; (2) there are no voids with sizes over 1–2 µm both in the baseline and nanostitched laminates; (3) the misorientation of plies (the in-plane difference of the average fiber direction from the nominal ply angle) is under 2°; (4) the misalignment (standard deviation of fiber orientations) has the same characteristics in the baseline and nanostitched laminates: it is in the range of 1.5°–3° in-plane and 2°–4° out-of-plane; the misalignment close to interfaces is increased in comparison with the misalignment deep within plies by ~1°. We conclude that the embedment of the nanostitch sensor does not alter the microstructural parameters of the laminate.