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Thermoplastic Composites 1
Polymer EngineeringPolymer Engineering
(MM3POE)(MM3POE)
http://www.nottingham.ac.uk/~eazacl/MM3POE
THERMOPLASTICTHERMOPLASTICCOMPOSITESCOMPOSITES
Thermoplastic Composites 2
ContentsContents
• Introduction
• Short Fibre MaterialsPropertiesManufacturing processesApplications
• Long Fibre MaterialsPropertiesManufacturing processesApplications
Thermoplastic Composites 3
COMPONENT
1. Introduction1. Introduction
THERMOPLASTICPOLYMERS
MATRIX
Prepreg sheetCommingled yarn/fabric
GMTsheet
SEMIFINISHED
Pellets/Granules
Platelets/Short fibre
Glass matContinuousfibre
REINF-ORCEMENT
Thermoplastic Composites 4
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
Thermoplastic Composites 5
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:
Thermoplastic Composites 6
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
Thermoplastic Composites 7
2.1 Glass reinforced thermoplastics2.1 Glass reinforced thermoplastics
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
Thermoplastic Composites 8
2.1 Glass reinforced thermoplastics2.1 Glass reinforced thermoplastics
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
Thermoplastic Composites 9
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)
-
Thermoplastic Composites 10
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
Thermoplastic Composites 11
2.4 Mechanical properties of2.4 Mechanical properties of SFRTPsSFRTPs
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.)
Thermoplastic Composites 12
2.4 Mechanical properties of2.4 Mechanical properties of SFRTPsSFRTPs
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
Thermoplastic Composites 14
2.4 Mechanical properties of2.4 Mechanical properties of SFRTPsSFRTPs
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
Thermoplastic Composites 15
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
Thermoplastic Composites 16
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
Thermoplastic Composites 17
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
Thermoplastic Composites 18
2.6 Applications of2.6 Applications of SFRTPsSFRTPs
Carbon/nylon 66 injectionmoulded mountain bike wheel
http://www.lnp.comVerton glass/pp door modulefor Mazda 6
http://www.lnp.com
Thermoplastic Composites 19
2.6 Applications of2.6 Applications of SFRTPsSFRTPs
Carbon/PEEK pump impellor
Glass/PEEK rocket ignitor
Thermoplastic Composites 20
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
Thermoplastic Composites 21
3.13.1 GMTsGMTs andand LFTsLFTs
Glass Mat Thermoplastic (GMT) – random fibre (chopped/continuous “swirl”) mat melt impregnated with thermoplastic resin
Material DensityKg/m3
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
Thermoplastic Composites 22
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
Thermoplastic Composites 23
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)
Thermoplastic Composites 24
3.13.1 GMTsGMTs andand LFTsLFTs -- ApplicationsApplications
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
Thermoplastic Composites 25
3.13.1 GMTsGMTs andand LFTsLFTs -- ApplicationsApplications
BATTERY TRAYSSupport battery weightChemical resistance (battery acid)
BMW battery tray<1 Kg incl. integral inserts
Dimensional stability (-30 to +80 C)www.quadrantplastics.com
Thermoplastic Composites 26
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)
Thermoplastic Composites 27
3.2 Continuous Fibre Reinforced3.2 Continuous Fibre Reinforced TPsTPs
Material DensityKg/m3
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
Thermoplastic Composites 28
3.2 Continuous Fibre Reinforced3.2 Continuous Fibre Reinforced TPsTPs
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
Thermoplastic Composites 29
3.2 Continuous Fibre Reinforced3.2 Continuous Fibre Reinforced TPsTPs
APC-2 Williams Formula 1 gear selector
APC-2 Apache helicopter horizontal stabiliser
Thermoplastic Composites 30
3.2 Continuous Fibre Reinforced3.2 Continuous Fibre Reinforced TPsTPs
Airbus A380www.airbus.com
Glass/PPS wing fixed leading edge (“J-nose”)Stork Fokker
Thermoplastic Composites 31
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
Thermoplastic Composites 32
3.4 Processing of3.4 Processing of LFRTPsLFRTPs
Industrial hot flow compression moulding facility for GMT/LFT
Thermoplastic Composites 33
3.4 Processing of3.4 Processing of LFRTPsLFRTPs
Compression moulding simulation for automotive front endhttp://www.m-base.de/main/express.html
Thermoplastic Composites 34
3.4 Processing of3.4 Processing of LFRTPsLFRTPs
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
Thermoplastic Composites 35
3.4 Processing of3.4 Processing of LFRTPsLFRTPs
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)