Automotive Composites Conference & Exhibition (ACCE ...

Foaming of Polymer

Composites: Automotive

Perspectives

Dr. Omar Faruk

Dr. Jimi Tjong

Prof. Mohini Sain

Automotive Composites Conference & Exhibition (ACCE)

September 5-7, 2018, Novi, MI, USA

Introduction

Composites Foaming

- Wood Fiber - Natural Fiber

- Carbon Fiber - Glass Fiber - Nano Fiber/Filler

Influence

- Fiber length/shape - Foaming agents types/contents

- Coupling agents - Processing parameters

Automotive Foaming

Conclusions

At a Glance

Composite Foaming

Homogeneous Nucleation

Heterogeneous Nucleation

*Source: Okolieocha et al. European Polymer Journal, 73 (2015) 500

Composite Foaming

Shape Factor S

* Plate-like

* Particle-like

* Topography of surface

*Source: Okolieocha et al. European Polymer Journal, 73 (2015) 500

Composite Foaming

Fiber Orientation

Cell Strut

*Source: Ameli et al. Carbon, 60 (2013) 379

*Source: Lightweight and Sustainable Materials for Automotive Applications,

Edited by Faruk, Tjong, Sain, CRC Press, 2017

Composite Foaming

PC+ 10% Carbon Fiber

PP + Wood Fiber 30 wt%

Composite Foaming: Wood Fiber

Foamed

area

Unfoamed area

*Source: Hou et al. International Journal of Fatigue, 59 (2014) 76

Composite Foaming: Wood Fiber

Soy based PU foam with 5% Wood Pulp

Composite Foaming: Natural Fiber

PP + Rice Husk 20 wt%

*Source: Petchwattana et al. Materials and Design, 32 (2011) 2844

Composite Foaming: Natural Fiber

HDPE + Wheat Straw Fiber 40 wt%

CFA: Azodicarbonamide

*Source: Babaei et al. Composites Part B, 56 (2014) 163

*Source: S. Hwang, Composites Part B, 98 (2016) 1

Composite Foaming: Carbon Fiber

*Source: Obaid et al. Cellular Polymers, 34 (2015) 6

Composite Foaming: Glass Fiber

Composite Foaming:Nanocomposite

*Source: James Lee et al. Composites Science & Technology, 65 (2005) 2344

*Source: Gedler et al. European Polymer Journal, 75 (2016) 190

Unfilled PC

1-step foams:

high relative density

PC with 5 wt% GnP

2-step foams :

Low relative density


PEI Polymer

*Source: Antunes et al. Materials Today, 3S (2016) S233


Pure chitosan and CNTs/CHI

nanocomposite foams compressed

to 50% of original length

- before (a and c)

- after (b and d).

*Source: Yan et al. Carbohydrate Polymers, 136 (2016) 1288


*Source: James Lee et al. Composites Science & Technology, 65 (2005) 2344


*Source: Antunes et al. Carbon, 49 (2011) 708



*Source: Duvigneau et al. European Polymer Journal, 65 (2015) 33

* Batch Foaming:

* CO2

at 55 bar

* 4 wt% nano particles

Influence of Fiber Content

Effect of wood flour

content on the cellular

structures of PLA:

(a) 0 wt%

(b) 10 wt%

(c) 20 wt%

(d) 30 wt%

(e) 40 wt%

Influence of Lignin

0% Lignin

10% Lignin

5% Lignin

15% Lignin

*Source: Luo et al. Industrial Crops and Products , 47(2013) 13

Soy based

rigid PU Foam

Influence of Foaming Agent

*Source: Soares et al. Polymer Testing, 32 (2013) 640

Influence of Coupling Agent

*Source: Yang et al. Journal of Reinforced Plastics & Composites, 34 (2015) 534

PP + Short Glass Fiber 20 wt%

CFA: Azodicarbonamide 12%

Synergistic Effect of Filler

*Source: Wu et al. Carbon, 95 (2015) 380

PLA : Polylactide Acid

CB : Carbon Black

CNT : Carbon Nanotube

Influence of Heating Time

Dissolving CO2

at 80°C

Graphene nanoplatelets 0.5 wt%

*Source: Gedler et al. Composites Part B, 92 (2016) 299

Influence of Foaming Process

*Source: Rezvanpanah et al. Carbon, 125 (2017) 32

MW: Microwave foaming

WB: Water bath foaming

FPD: Fast pressure drop foaming

PS+CNT 1 wt%

Influence of Foaming Process

*Source: Ellingham et al. Polymer, 117 (2017) 132

Influence of Processes

Injection MoldingCompression

Molding

Extrusion

PP + Wood Fiber 30 wt%

Influence of Fiber Length

*Source: Narasimman et al. Materials Letters, 144 (2015) 46

Influence of Processing Parameters

* Wood fiber-PP composites (Fiber content 30 wt%)

*Source: Tang et al. The Journal of Supercritical Fluids, Article in Press (2018)

Influence of Pressure & Temperature

8 MPa

12 MPa 14 MPa

10 MPa 40 °C 50 °C

60 °C 70 °C

CNT-

Silicone

Rubber

Foam

CNT

Content-

0.5 wt%

*Source: Srithep et al. Cellulose, 117 (2017) 132

Influence of Nanocellulose Fiber

Influence of Chain length

CNF-Trimethylammonium bromide

Foam

Dodecyltrimethylammonium bromide

Tetradecyltrimethylammonium bromide

Hexadecyltrimethylammonium bromide

C12

C14

C16

*Source: Mariano et al. Carbohydrate Polymers, 195 (2018) 153

Automotive Foaming

*Source: Ford Media

*Source: Woodbridge Group

MuCell Foaming of Cam Cover

*Source: Elringklinger

PA 6 + GF 35%

Automotive Foamed Parts

*Source: Trexel Automotive

Concluding Remark

*Source: Global Market Insights Inc., Research Report

Published Date: January 15, 2018

The global Automotive Composites Market size in

terms of revenue:

• USD - 15 Billion in 2016

• USD - 24 Billion by 2024

The global Automotive Composites Market size in

terms of volume:

• Volume - 2666 Kilo tons in 2016

• Volume - 4000 Kilo tons by 2024

Concluding Remark

*Additive Manufacturing of Syntactic Foams: Part 1: Development, Properties, and Recycling Potential of

Filaments, Singh et al. Journal of Minerals, March 2018, Vol.70, Page 303

3D Printing of Composite Foam HDPE with 40 wt.% fly-ash

Thanks

DR. Omar Faruk

Research & Development Engineer

Powertrain Engineering R&D Centre

Ford Motor Company

Windsor

CANADA

Em@il: [email protected]

DR. Omar Faruk

Adjunct Professor

Centre for Biocomposites and

Biomaterials Processing

University of Toronto

CANADA

Em@il: [email protected]

Automotive Composites Conference & Exhibition (ACCE ...

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