A char removal protocol to visualize fiber cross‐sections of carbon/epoxy composites subjected to flame

Abstract Post‐crash fires obscure or destroy critical fracture surfaces needed to determine the origin of aircraft structural failures. Our goal is to eliminate combustion residue from carbon fiber‐reinforced polymer composites to enable fractographic examination during aviation accident investigations. In this work, combustion residues were removed from burned Hexcel SGP370‐8H/8552 woven‐fabric carbon/epoxy specimens by nitric/sulfuric acid oxidations. Scanning electron microscopy identified various types of char obscuring the fiber ends. For char removal, the burned specimens were immersed in a nitric acid/sulfuric acid/water solution (0.18 wt.%, 96.25 wt.%, 3.57 wt.%) at elevated temperatures (75–150°C). Higher temperatures enhanced nitric acid decomposition in this highly acidic, low‐water environment, accelerating char oxidation and progressively enhancing the extent of char removal. At lower temperatures (T < 100°C), char deposits were partially oxidized after 60 mins. At 125 and 150°C, the char was removed within 30 mins of immersion. The epoxy matrix both chemically decomposed and oxidized and the char oxidized during these oxidation treatments. Gas evolution and soluble products dissolved in the HNO₃/H₂SO₄ media. The damage morphology created by the sawing action on the fiber ends, created before flame exposure, remained clearly visible after the acid oxidations. This occurs because oxidation rates at the carbon fiber ends are much slower than the char oxidation in these acid treatments. If the acid treatment temperature raised above 185°C, then this sawing‐induced fiber damage morphology will also be destroyed. This preliminary understanding can be applied to develop a comprehensive forensic analysis procedure for post‐crash fire investigations. Highlights Flame exposure of sawed specimen cross‐sections leads to char formation, obscuring fiber damage morphologies. HNO₃/H₂SO₄ oxidations at elevated temperatures (75–150°C) resulted in char removal from fiber ends. Higher temperatures (T = 125 and 150°C) accelerated char oxidation. The sawing of carbon/epoxy composites caused extensive fiber damage and ply delamination. Residual decomposed resin matrix and char oxidized faster than the carbon fibers and the fiber sawing‐induced fiber damage morphologies created before flame exposure and were preserved after char removal.