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<p>To address the conductivity loss in fractured carbon fibers (CFs) requires innovative solutions to improve both electrical and mechanical connections. Joining fracture CFs with carbon or metal is a skillful way to solve this problem and improve the performance and reliability of bilayer composites. This study debates an innovative approach for joining fractured CFs using electrothermal induced solvent evaporation and meniscus-confined electrochemical deposition. These methods aim to create bilayer of carbon nanotubes (CNTs) and silver (Ag) around the fractured CFs, with the confidence of boosting both electrical and mechanical connections. Real time monitoring showed sequential bilayer assembly with CNT bridging completed in 6.0&#xa0;min followed by Ag layer formation in 17.5&#xa0;min, yielding hybrid interfaces. The microstructural analysis revealed that the CNTs cladding layer exhibited a smooth surface. The Ag cladding layer also displayed a smooth surface without any holes and cracks present on joint surfaces. Electrical testing, supported by statistical analysis, demonstrates that the incorporation of CNTs and Ag in a bilayer configuration significantly enhances electrical conductivity, reducing the average resistance from pristine CF (34.0 ± 1.7 Ω) to as low as 14.3 ± 3.73 Ω in the engineered joints, while confirming good reproducibility. Mechanical testing demonstrates that, under optimized conditions, the joined CFs exhibit plastic fracture with strength comparable to the original fiber, while statistical analysis confirms highly consistent strain (7.88 ± 0.05%) and moderate stress variability (203.93 ± 32.93&#xa0;MPa), indicating good reproducibility with acceptable dispersion in mechanical performance.</p>

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Restoring electrical conductivity and mechanical integrity of fractured carbon fibers via CNTs–Ag bilayer interfaces

  • 期刊论文

  • 发表日期：

    2026年5月5日

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  • Akhtar Iqbal,
  • Muhammad Ilyas Khan,
  • Amir Ali Khan,
  • Dezhi Ma,
  • Di Zhang,
  • Zhen Luo

摘要

To address the conductivity loss in fractured carbon fibers (CFs) requires innovative solutions to improve both electrical and mechanical connections. Joining fracture CFs with carbon or metal is a skillful way to solve this problem and improve the performance and reliability of bilayer composites. This study debates an innovative approach for joining fractured CFs using electrothermal induced solvent evaporation and meniscus-confined electrochemical deposition. These methods aim to create bilayer of carbon nanotubes (CNTs) and silver (Ag) around the fractured CFs, with the confidence of boosting both electrical and mechanical connections. Real time monitoring showed sequential bilayer assembly with CNT bridging completed in 6.0 min followed by Ag layer formation in 17.5 min, yielding hybrid interfaces. The microstructural analysis revealed that the CNTs cladding layer exhibited a smooth surface. The Ag cladding layer also displayed a smooth surface without any holes and cracks present on joint surfaces. Electrical testing, supported by statistical analysis, demonstrates that the incorporation of CNTs and Ag in a bilayer configuration significantly enhances electrical conductivity, reducing the average resistance from pristine CF (34.0 ± 1.7 Ω) to as low as 14.3 ± 3.73 Ω in the engineered joints, while confirming good reproducibility. Mechanical testing demonstrates that, under optimized conditions, the joined CFs exhibit plastic fracture with strength comparable to the original fiber, while statistical analysis confirms highly consistent strain (7.88 ± 0.05%) and moderate stress variability (203.93 ± 32.93 MPa), indicating good reproducibility with acceptable dispersion in mechanical performance.