The Application of a Non-Newtonian Fluid as a Protective Layer for a CFRP Material Subjected to Low-Energy Impact Loads

One of the key challenges in using CFRP (Carbon Fiber Reinforced Polymer) structures is their susceptibility to low-energy impact damage, often indicated as barely visible impact damage (BVID). Such defects are difficult to detect and can compromise structural integrity. This study investigates the use of immobilized non-Newtonian fluids (NNF) as protective layers for CFRP composites subjected to low-energy impacts. Experimental tests were carried out with an Instron 9440 drop-weight impact tower (impact energy range 5–40 J) and high-speed imaging, comparing NNF coatings with rubber-based, caoutchouc-based, and spray-based protective layers. Non-destructive evaluation using computed tomography confirmed that NNF coatings dissipate impact energy through shear-thickening behavior, reducing delamination while preserving clear visual indicators of the impact site. Furthermore, the study assessed post-impact fatigue bending performance, revealing that the inclusion of NNF—either as an outer layer or as part of a sandwich structure—significantly enhanced the residual fatigue strength of the composites. Moreover, NNFs inherently preserve visible traces of penetration, thereby improving the detectability of impact locations through both unaided visual inspection and advanced imaging modalities such as computed tomography. In addition to external coatings, NNF was applied as a core in sandwich structures, demonstrating improved impact resistance compared to monolithic CFRP laminates and conventional CFRP–foam sandwiches. The protective performance was found to depend on fluid thickness and threshold shear rates required for viscosity transition, indicating that thicker layers do not always provide superior protection.