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Thermoplastic Composites 1

Polymer EngineeringPolymer Engineering

(MM3POE)(MM3POE)

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

THERMOPLASTICTHERMOPLASTIC

COMPOSITESCOMPOSITES




ContentsContents

• Introduction• Short Fibre Materials

Properties

Manufacturing processes

Applications• Long Fibre Materials

Properties

Manufacturing processes

Applications




COMPONENT

1. Introduction1. Introduction

THERMOPLASTIC

POLYMERSMATRIX

Prepreg sheet Commingled yarn/fabric

GMT

sheet

SEMI FINISHED

Pellets/ Granules

Platelets/ Short fibre

Glass mat Continuousfibre

REINF-ORCEMENT




2. Short Fibre Reinforced 2. Short Fibre Reinforced

Thermoplastics ( 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 properties

Higher cost & processing difficulties

Anisotropic & non-uniform material properties

• Mineral reinforcement (eg. mica, clay):

Enhanced performance

eg. mech. props, dimensional stability

Often at lower cost BUT similar processing difficulties

Moulding compounds supplied as pelletspellets in two

forms:




2.1 Glass reinforced thermoplastics2.1 Glass reinforced thermoplastics

Material Density

Kg/m3

Tensile

StrengthMPa

Flexural

ModulusGPa

Impact

StrengthkJ/m

2

HDToC

Thermal

Expansion10

6/ K

ABS 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

F l e x u

r a l M o d u l u s ( G P a )

ABS Acetal PC PBT HDPE PP PS

Flexural Moduli of SFRTPs

30% glass Base resin

0

20

40

60

80

100

120

140

T e n s i l e S t r e n g t h ( M P 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 h o r t t e r m

m o d u l u s

35% glass

0% glass




2.22.2--2.3 Carbon/2.3 Carbon/ Aramid Aramid /Long Fibre /Long Fibre

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

Material Density

Kg/m3

Tensile

StrengthMPa

Flexural

ModulusGPa

Impact

StrengthkJ/m

2

HDToC

Thermal

Expansion10

6/ K

PEK 30% glass 1530

(+230)

170

(+65)

9.0

(+5.3)

9.0

(+2.0)

358

(+172)

-

PEK30% 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 66

33% glass

1390

(+250)

180d/115c

(+95/+55)

8.7d/5.5c

(+5.8/+4.4)

9d/12c

(+3/-10)

245

(+145)

-

Nylon 66

50% 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 of 2.4 Mechanical properties of SFRTPsSFRTPs

• Mechanical properties of SFRTPs depend on:

Fibre length (aspect ratio)Fibre volume fraction

Fibre orientation

σ





If fibres are parallel to loading, then:

where

V f = fibre volume fraction

E f , E m = fibre & matrix (polymer) moduli

m f f f E V E V E )1(1max

The correction factor, η1, is given by:

na

na)tanh(11

where a = aspect ratio and n depends on fibre distribution and

fibre & polymer properties:

)/2ln(

2

d R E

Gn

f

m

=E (short)

E (contin.)





Fibre Length Correction Factor

Glass/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)

C o r r e c t i o n

F a c t o r

n = 0.208

d = 22 m

na

na)tanh(11

)/2ln(

2

d R E

Gn

f

m

a = 100





If fibres are parallel to loading,then:

m f f f E V E V E )1(

1max

In reality fibres are NOT parallelto loading, so that:

2D random

3D random

E 8

3 Emax

E 5

1 Emax




2.5 Processing of 2.5 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 of 2.5 Processing of SFRTPsSFRTPs

Viscosity at 25 s-1

for PA 66

Data 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)

V i s c o s i t y

( P a s ) 180

oC

200oC




2.6 Applications of 2.6 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 SYSTEMS

Compared to metal manifolds:Metal - machining after casting

Surfaces rougher than composites

Lower mass of composite (up to 50%)

Lower thermal conductivity, so fasterwarm-up & reduced emissions

Composite manifolds offer ~ 3%

add. power due to improved air flow

Manufacture of hollow parts:

“Lost-core” technique

or

2 part, vibration welding





Carbon/nylon 66 injection

moulded 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 Reinf Reinf ..

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 thermosets

Matrix brittlenessIngress by solventsLimited shelf lifeSlow curing cycle

Advantages of thermoplastics

ToughnessResistance to chemicalsUnlimited shelf lifeHigh volume productionRecycling of scrapRepair of damaged structures

Disadvantages of thermoplasticsHigh viscosity High temperature processing




3.13.1 GMTsGMTs and and LFTsLFTs

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

Material Density

Kg/m3

Tensile

StrengthMPa

Flexural

ModulusGPa

Impact

StrengthkJ/m2

HDToC

Thermal

Expansion106 / K

C100 F23Mf 23% chopped fibre

1060 60 3.0 - 145 30-40

B100 F30

Mf 30% chopped fibre

1130 67 4.3 70 150 20-30

B100 F40

Mf 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 and and 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 and and LFTsLFTs -- Applications Applications

VEHICLE FRONT ENDS

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

VW Golf front end - GMT 3.7kg (35% lighter than Steel)





SEAT STRUCTURES

Strength, stiffness & toughnessParts integration, moulded insertsRear impact protection

Audi TT rear seat back 3.5 Kg incl steel frame & carpet

Integral seat belt support www.quadrantplastics.com





BATTERY TRAYS

Support battery weightChemical resistance (battery acid)

BMW battery tray

<1 Kg incl. integral insertsDimensional stability (-30 to +80 C)

www.quadrantplastics.com




3.2 Continuous Fibre Reinforced 3.2 Continuous Fibre Reinforced TPsTPs

Best mechanical properties are achieved with CONTINUOUSCONTINUOUSFIBRESFIBRES (ideally aligned)

UD tapes & laminates

Woven fabrics

Thermoplastic matrices can be combined with aligned fibres by:

Film stacking Hybrid (commingled) yarns Powder impregnation

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





Material Density

Kg/m

3Tensile

StrengthMPa

Flexural

ModulusGPa

Impact

StrengthkJ/m2

HDTo

C

Thermal

Expansion106

/ K Twintex 1/1

Vf 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 UD

Vf 35% glass/PP

1480 720/11 21/- 383 156 7

Twintex UD

Vf 50% glass/PP

1750 700/- 32/- 330 159 -

TEPEX 101 1/1

Vf 47% glass/PA66

1800 380 22 - 255 15

CETEX 7781 1/1

Vf 50% glass/PEI

1910 465 26 - 200

service 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. 1/1

Vf 56% carbon/PA12

1440 801 52 - - -

SUPreM IM7 UD

Vf 60% carbon/PEEK

1600 2400/68 120/- - 250

service temp

-

Cytec APC-2 UD

Vf 63% carbon/PEEK

1600 2400/82 138/- - 250

service temp

-

Table 3: Properties of aligned fibre composites





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

www.twintex.com

Peugeot 806 bumper -

woven glass/pp Twintex combined with GMT www.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 of 3.3 Mechanical properties of LFRTPsLFRTPs

0

10

20

30

40

50

60

70

0 20 40 60 80 100

Fibre Volume Fraction (%)

L o n g i t u d i n a l M o d u l u s ( G P a )

UD

0/900/+-45/90

+/-452D Random

m f f f E V E V E )1(01

iia 4

0 cos




3.4 Processing of 3.4 Processing of LFRTPsLFRTPs

Industrial hot flow compression moulding facility for GMT/LFT





Compression moulding simulation for automotive front end

http://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

rapid

transfer

device

infra-red oven

control

pyrometers

emittersreflectors

transfer

frame

heated

composite

shaped

rubber tool

moving bolster blank holder

to apply

membrane

stresses

rigid lower tool

fast acting hydraulic press

textile sheet

for 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. Summary 4. Summary

0.01

0.1

1

10

1 10 100

Specific Stiffness (MNm/kg)

S p e c i f i c S t r e n g t h ( M N m / k g )

PP

PA66

GMT/LFT

PA66/glass

SFRTP

PEEK/carbon

SFRTP

Twintex/

Plytron

Steel

Aluminium/

Titanium alloys

TEPEX

carbon/PA66

APC-2/SUPreM

1/1

APC-2/SUPreM

UD

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