Fabrication and characterization of three-dimensional cellular-matrix composites reinforced with woven carbon fabric

A low-density three-dimensional cellular-matrix composite reinforced with woven carbon fabric (3DCMC), was fabricated by means of a pressure-quenching molding technique with nitrogen gas as the blowing agent. Epoxy resins in the interstices of yarns in the 3DCMC samples were vacated during the foaming process and needle shaped voids were also generated between fibers in yarns. The average density of the 3DCMC samples was about 103 kg/m3, and their density reduction was 28–37% compared with a regular matrix composite with the same preform. The 3DCMC has 32–42% higher specific tensile strength, 14–37% greater specific tensile modulus, a lower specific flexure strength but 35% higher specific tangent modulus in 3-point bending, a 30–40% higher specific impact energy absorption at an impact velocity around 120 m/s and a similar specific energy absorption at about 220 m/s. Meanwhile, the 3-point bending and impact test results of 3DCMC showed that they have different fracture mechanisms from that of 3DRMC.