Polymer Engineering (MM3POE) - University of...

Thermoplastic Composites 1

Polymer EngineeringPolymer Engineering

(MM3POE)(MM3POE)

http://www.nottingham.ac.uk/~eazacl/MM3POE

THERMOPLASTICTHERMOPLASTICCOMPOSITESCOMPOSITES


ContentsContents

• Introduction

• Short Fibre MaterialsPropertiesManufacturing processesApplications

• Long Fibre MaterialsPropertiesManufacturing processesApplications


COMPONENT

1. Introduction1. Introduction

THERMOPLASTICPOLYMERS

MATRIX

Prepreg sheetCommingled yarn/fabric

GMTsheet

SEMIFINISHED

Pellets/Granules

Platelets/Short fibre

Glass matContinuousfibre

REINF-ORCEMENT


2. Short Fibre Reinforced2. Short Fibre ReinforcedThermoplastics (Thermoplastics (SFRTPsSFRTPs))

• Most TP resins can be combined with fibres/fillers toenhance properties for injection moulding/ extrusion

eg. stiffness, strength, impact, heat distortionthermal expansion, friction & wear

• Reinforcement comes in twoforms - fibrous & mineral:

l

d

Aspect ratio,a = l/d


2.2. SFRTPsSFRTPs

• Fibrous reinforcement (eg. glass, carbon, Kevlar):Improved mechanical & thermal propertiesHigher cost & processing difficultiesAnisotropic & non-uniform material properties

• Mineral reinforcement (eg. mica, clay):Enhanced performance

eg. mech. props, dimensional stabilityOften at lower cost BUT similar processing difficulties

Moulding compounds supplied as pelletspellets in twoforms:


2.1 Glass reinforced thermoplastics2.1 Glass reinforced thermoplastics

Material DensityKg/m3

TensileStrength

MPa

FlexuralModulus

GPa

ImpactStrength

kJ/m2

HDToC

ThermalExpansion

106 / KABS 30% glass 1280

(+230)100

(+59)7.6

(+5.4)1.4

(-3.0)104

(+13)16

(-37)Acetal 30% glass 1630

(+210)134

(+73)9.7

(+6.9)1.8

(+0.5)163

(+53)22

(-23)PC 30% glass 1430

(+230)128

(+66)8.3

(+6.0)3.7

(+1.0)149

(+20)13

(-24)PBT 30% glass 1520

(+210)134

(+75)9.7

(+7.4)2.5

(+1.3)221

(+167)12

(-41)HDPE 30% glass 1170

(+220)69

(+51)6.2

(+4.8)1.1

(+0.7)127

(+88)27

(-33)PP 30% glass 1120

(+210)67

(+43)3.8

(+2.6)3.0

(+2.6)146

(+89)20

(-20)PS 30% glass 1280

(+210)93

(+45)9.0

(+5.9)1.0

(+0.55)102

(+20)19

(-17)

Table 1: Mechanical and thermal properties of SFRTPs



0

1

2

3

4

5

6

7

8

9

10

Flex

ural

Mod

ulus

(GP

a)

ABS Acetal PC PBT HDPE PP PS

Flexural Moduli of SFRTPs

30% glass Base resin

0

20

40

60

80

100

120

140

Tens

ileS

tren

gth

(MP

a)

ABS Acetal PC PBT HDPE PP PS

Tensile Strength of SFRTPs

30% glass Base resin



Creep at 40 C for PA 66 (10MPa load)Data from Bayer AG Durethan Range

0

20

40

60

80

100

120

1 10 100 1000 10000

Time (hours)

%S

ho

rtte

rmm

od

ulu

s

35% glass

0% glass


2.22.2--2.3 Carbon/2.3 Carbon/AramidAramid/Long Fibre/Long Fibre

Table 1: Mechanical and thermal properties of SFRTPs (contd)Material Density

Kg/m3Tensile

StrengthMPa

FlexuralModulus

GPa

ImpactStrength

kJ/m2

HDToC

ThermalExpansion

106 / KPEK 30% glass 1530

(+230)170

(+65)9.0

(+5.3)9.0

(+2.0)358

(+172)-

PEK 30% carbon 1420(+120)

225(+120)

17.9(+14.6)

8.0(+1.0)

360(+17.4)

-

PEEK 30% glass 1490(+170)

157(+65)

10.3(+6.7)

10.0(+2.0)

315(+155)

-

PEEK 30% carbon 1440(+120)

208(+116)

13.0(+9.4)

9.0(+1.0)

315(+155)

-

PES 30% glass 1600(+230)

140(+56)

8.4(+5.8)

9.0(+1.0)

216(+13)

-

Nylon 6633% glass

1390(+250)

180d/115c(+95/+55)

8.7d/5.5c(+5.8/+4.4)

9d/12c(+3/-10)

245(+145)

-

Nylon 6650% glass

1570(+430)

200d/155c(+115/+95)

12d/9.6c(+9.1/+8.5)

11d/13c(+5/-9)

250(+150)

-

Nylon 66 (Verton)50% glass

1570(+430)

230d/165c(+145/+105)

15.8d/11.2c(+12.9/+10.1)

27d/37c(+21/+15)

261(+161)

-


2.4 Mechanical properties of2.4 Mechanical properties of SFRTPsSFRTPs

• Mechanical properties of SFRTPs depend on:Fibre length (aspect ratio)Fibre volume fractionFibre orientation

σ



If fibres are parallel to loading, then:

whereVf = fibre volume fractionEf , Em = fibre & matrix (polymer) moduli

mfff EVEVE )1(1max

The correction factor, η1, is given by:

nana)tanh(

11

where a = aspect ratio and n depends on fibre distribution andfibre & polymer properties:

)/2ln(2

dREG

nf

m

= E (short)

E (contin.)



Fibre Length Correction FactorGlass/Nylon, 30% Vf

0.0

0.2

0.4

0.6

0.8

1.0

0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5

Fibre Length (mm)

Co

rrec

tio

nF

acto

r

n = 0.208d = 22 m

nana)tanh(

11

)/2ln(2

dREG

nf

m

a = 100



If fibres are parallel to loading,then:

mfff EVEVE )1(1max

In reality fibres are NOT parallelto loading, so that:2D random

3D random

E 83 Emax

E 51 Emax


2.5 Processing of2.5 Processing of SFRTPsSFRTPs

INJECTION MOULDINGINJECTION MOULDING is by far the most important process

In comparison to base polymers, SFRTPs can lead to:• Increased wear on moulding equipment• Anisotropic material properties• Higher melt viscosity


2.5 Processing of2.5 Processing of SFRTPsSFRTPs

Viscosity at 25 s-1 for PA 66Data from Bayer AG Durethan Range

0

100

200

300

400

500

600

700

800

0 5 10 15 20 25 30 35

Glass fibre content (% mass)

Vis

cosi

ty(P

as)

180 oC

200 oC


2.6 Applications of2.6 Applications of SFRTPsSFRTPs

General Motors' Vortec 4200 Inline six-cylinder engine features arobust air intake manifoldmade by Montaplast of North America,

Inc. using DuPont Zytel® glass-reinforced nylonhttp://www.dupont.com/

AIR-INTAKE SYSTEMSCompared to metal manifolds:

Metal - machining after castingSurfaces rougher than compositesLower mass of composite (up to 50%)Lower thermal conductivity, so fasterwarm-up & reduced emissionsComposite manifolds offer ~ 3%add. power due to improved air flow

Manufacture of hollow parts:“Lost-core” technique

or2 part, vibration welding



Carbon/nylon 66 injectionmoulded mountain bike wheel

http://www.lnp.comVerton glass/pp door modulefor Mazda 6

http://www.lnp.com



Carbon/PEEK pump impellor

Glass/PEEK rocket ignitor


3. Long/Continuous Fibre3. Long/Continuous Fibre ReinfReinf..Thermoplastics (Thermoplastics (LFRTPsLFRTPs))

• For medium/high performance, long fibres are needed forrequired mechanical properties

• Long/continuous fibre thermoplasticsthermoplastics have been developedas alternatives to thermosetsthermosets

Disadvantages of thermosetsMatrix brittlenessIngress by solventsLimited shelf lifeSlow curing cycle

Advantages of thermoplasticsToughnessResistance to chemicalsUnlimited shelf lifeHigh volume productionRecycling of scrapRepair of damaged structures

Disadvantages of thermoplasticsHigh viscosityHigh temperature processing


3.13.1 GMTsGMTs andand LFTsLFTs

Glass Mat Thermoplastic (GMT) – random fibre (chopped/continuous “swirl”) mat melt impregnated with thermoplastic resin


TensileStrength

MPa

FlexuralModulus

GPa

ImpactStrength

kJ/m2

HDToC

ThermalExpansion

106 / KC100 F23Mf 23% chopped fibre

1060 60 3.0 - 145 30-40

B100 F30Mf 30% chopped fibre

1130 67 4.3 70 150 20-30

B100 F40Mf 38% chopped fibre

1200 100 5.2 51 155 15-25

G100 F40 Mf 40%continuous fibre

1220 75 5.8 64 155 25-28

C100 UD45 Mf 23%chopped/22% UD

1280 270/46 9.6/4.5 201 - 15-25/40-50

Table 2: Properties of Quadrant Plastic Composites glass/PP GMTs

PP 900 25 1 <1 50 100


3.13.1 GMTsGMTs andand LFTsLFTs

Direct Long-Fibre Thermoplastic (LFT-D) – fibre (glass) strandsand polymer combined & extruded directly to produce analternative to GMT

http://www.ptonline.com


3.13.1 GMTsGMTs andand LFTsLFTs -- ApplicationsApplications

VEHICLE FRONT ENDSFatigue (70 million cycles)Dynamic loading up to 100 oCAttachment pts (moulded inserts)Parts integrationCost & weight reductions

VW Golf front end - GMT3.7kg (35% lighter than Steel)



SEAT STRUCTURESStrength, stiffness & toughnessParts integration, moulded insertsRear impact protection

Audi TT rear seat back3.5 Kg incl steel frame & carpet

Integral seat belt supportwww.quadrantplastics.com



BATTERY TRAYSSupport battery weightChemical resistance (battery acid)

BMW battery tray<1 Kg incl. integral inserts

Dimensional stability (-30 to +80 C)www.quadrantplastics.com


3.2 Continuous Fibre Reinforced3.2 Continuous Fibre Reinforced TPsTPs

Best mechanical properties are achieved with CONTINUOUSCONTINUOUSFIBRESFIBRES (ideally aligned)

UD tapes & laminatesWoven fabrics

Thermoplastic matrices can be combined with aligned fibres by:

Film stacking Hybrid (commingled) yarns Powder impregnation

Also: polymerisation control (eg. APCAPC--22)




TensileStrength

MPa

FlexuralModulus

GPa

ImpactStrength

kJ/m2

HDToC

ThermalExpansion

106 / KTwintex 1/1Vf 35% glass/PP

1500 300 13 180 159 13

Plytron 1/1Vf 35% glass/PP

1480 360 17 - 156 20

Twintex 1/1Vf 50% glass/PET

1950 440 23 205 257 15

Plytron UDVf 35% glass/PP

1480 720/11 21/- 383 156 7

Twintex UDVf 50% glass/PP

1750 700/- 32/- 330 159 -

TEPEX 101 1/1Vf 47% glass/PA66

1800 380 22 - 255 15

CETEX 7781 1/1Vf 50% glass/PEI

1910 465 26 - 200service temp

-

TEPEX 201 1/1Vf 48% carbon/PA66

1500 755 44 - 255 -

CETEX T300 1/1Vf 50% carbon/PEI

1510 665 47 - 200service temp

-

Schappe Techs. 1/1Vf 56% carbon/PA12

1440 801 52 - - -

SUPreM IM7 UDVf 60% carbon/PEEK

1600 2400/68 120/- - 250service temp

-

Cytec APC-2 UDVf 63% carbon/PEEK

1600 2400/82 138/- - 250service temp

-

Table 3: Properties of aligned fibre composites



VT Halmatic 6.7m rigid inflatable boatVacuum formed using woven glass/pp Twintex

www.twintex.com

Peugeot 806 bumper -woven glass/pp Twintexcombined with GMTwww.twintex.com



APC-2 Williams Formula 1 gear selector

APC-2 Apache helicopter horizontal stabiliser



Airbus A380www.airbus.com

Glass/PPS wing fixed leading edge (“J-nose”)Stork Fokker


3.3 Mechanical properties of3.3 Mechanical properties of LFRTPsLFRTPs

0

10

20

30

40

50

60

70

0 20 40 60 80 100

Fibre Volume Fraction (%)

Lo

ng

itu

din

alM

od

ulu

s(G

Pa)

UD

0/900/+-45/90

+/-452D Random

mfff EVEVE )1(01

iia 40 cos


3.4 Processing of3.4 Processing of LFRTPsLFRTPs

Industrial hot flow compression moulding facility for GMT/LFT



Compression moulding simulation for automotive front endhttp://www.m-base.de/main/express.html



Vacuum consolidation for commingled thermoplastic composites(www.twintex.com)

Sealant

Release filmVacuumConnector

Vacuum bag

Tool

Twintex

Bleeder

Frame

Sealant

Release filmVacuumConnector

Vacuum bag

Tool

Twintex

Bleeder

Frame



formed part

rapidtransferdevice

infra-red oven

controlpyrometers

emittersreflectors

transferframe

heatedcomposite

shapedrubber tool

moving bolsterblank holder

to applymembrane

stresses

rigid lower tool

fast acting hydraulic press

textile sheetfor forming

accumulators

Matched mould forming for aligned thermoplastic composites(M.D. Wakeman- Fig. 6.15 in “Design & Manufacture of Textile Composites”, ed.

A C Long, Woodhead Publishing Ltd 2005)


4. Summary4. Summary

0.01

0.1

1

10

1 10 100

Specific Stiffness (MNm/kg)

Sp

ecif

icS

tren

gth

(MN

m/k

g)

PP

PA66

GMT/LFT

PA66/glassSFRTP

PEEK/carbonSFRTP

Twintex/Plytron

Steel

Aluminium/Titanium alloys

TEPEXcarbon/PA66

APC-2/SUPreM1/1

APC-2/SUPreMUD

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