Abstract
The use of fibre-reinforced polymer composites as a lightweight metal replacement for automotive componentry is constantly expanding into new and more challenging application areas (e.g. whole range of under-bonnet, exhaust applications and other automotive components), where service temperatures are not expected to go beyond 150 °C. This study seeks to provide some useful baseline data on the bending stiffness performance of a large range of commercially available composite moulding compounds, in order to provide guidance in selecting appropriate materials for various applications requiring higher operating temperatures, where retention of bending stiffness is a key parameter. Whilst glass transition data can give some indication, this study seeks to go further. Three point bending flexural tests and Dynamic Mechanical Analysis were used to investigate and compare properties both at ambient and 150 °C comparing various composite systems, particularly phenolics, one of the fastest-growing systems in the thermoset moulding compounds market.
Highlights
Polymer matrix composite materials offer a cheap and lightweight alternative to metal componentry and feature as part of the primary load-bearing structures in military and commercial aviation aircraft [1]
This study focuses on the viability of using moulding compounds for application in higher temperature environments up to 150 C, such as the engine compartment, manifolds covers, battery boxes, ducting, exhaust and other automotive components, which are prime targets for composites as lightweight metal replacements [4,5,6]
In this study various types of commercially available moulding compounds were used with a special focus on heat resistant phenolic based resin systems, which can operate at elevated temperatures
Summary
Polymer matrix composite materials offer a cheap and lightweight alternative to metal componentry and feature as part of the primary load-bearing structures in military and commercial aviation aircraft [1]. Further more, the whole poly-aryl-ether-ketone (PAEK) family, which includes poly-ether-ether- ketone (PEEK) and poly-ether-ketone-ketone (PEKK) and their composites are widely used in aerospace applications due to the inherent weight saving, chemical and thermal resistance, and me chanical performance [3]. Whilst some of these grades can withstand sustained thermal excursions in the region of 400 C, there are difficulties. These materials require complex and lengthy processing operations, and are high cost. Polymer composite compression moulding compounds and composite injection moulding grades are the main two types of composite sys tems/manufacturing techniques most exploited for automotive applications
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