Carbon Fiber Reinforced Polyphenylene Sulfide Research Articles

Infrared on-site heating for material extrusion additive manufacturing of carbon fiber filled polyphenylene sulfide and its nano-graphene-reinforced alternatives

This study investigates the impact of infrared heating and annealing on the mechanical properties of carbon fiber-reinforced polyphenylene sulfide (CF-PPS) and graphene nanoplatelet (GNP)-reinforced CF-PPS composites in Material extrusion (MEX) additive manufacturing. GNP/CF-PPS composites are prepared by mechanically mixing CF-PPS plastic particles with GNP particles and subjecting them to infrared heating and annealing treatments during the three-dimensional (3D) printing process. Three-point bending tests assess the mechanical properties of the samples. The results reveal that the 0.03 wt.% GNP/CF-PPS sample, subjected to infrared heating followed by annealing, exhibits a 30% increase in bending strength compared to pure CF-PPS, demonstrating that the combined treatment significantly enhances mechanical performance. Microscopy observations using a Keyence VH7000 digital optical microscope and a scanning electron microscope (SEM) confirm that GNP addition and infrared irradiation lead to reduced surface roughness and fewer fracture cross-sectional pores. The interlayer bonding improves notably, indicating enhanced internal density and structural stability. Furthermore, differential scanning calorimetry analysis shows a 20% increase in crystallinity for heat-treated samples, contributing to better interlaminar bonding and reduced temperature gradients during printing. Finite element simulations using MATLAB and ABAQUS software corroborate these findings, demonstrating that infrared heating proves more effective than varying GNP content alone in reducing deformation, residual stress, and temperature differences during the MEX process. These results provide valuable insights into improving the mechanical properties and stability of MEX-manufactured large-dimensional composite materials through optimized thermal management.

Ply-ply friction behavior between unidirectional thermoplastic prepreg plies during thermoforming: Characterization and modeling

The ply-ply friction behavior of unidirectional carbon fiber reinforced polyphenylene sulfide (UD CF/PPS) prepreg in thermoforming was investigated through an improved pull-through testing system. The effects of temperature, normal force and slipping velocity were considered in testing. The results indicated the existence of three key mechanisms underlying slipping: namely the resin shear, fiber–fiber contact and fiber-resin interaction. A three-stage division of the experimental curve was proposed, and several factors were defined to establish a quantitative definition of the ply-ply friction behavior. The results showed that the influence of slipping velocity is particularly evident. Its post-yield stress (12.8 kPa), steady-state CoF (0.118) and residual stress (0.705 kPa) were the highest, exhibiting the largest changes of 957.9 %, 736.9 % and 47.2 %, respectively. This indicated the strong contribution of resin in ply-ply friction. In addition, the Stribeck analysis also suggested the dominance of hydrodynamic lubrication condition in slipping. Based on the experimental results, a simple phenomenological model was proposed based on experimental curves to accurately describe the effects of processing parameters. This work presents a comprehensive characterization of the ply-ply friction behavior of UD CF/PPS prepreg in thermoforming, providing a substantial experimental foundation for the subsequent simulation research.

Manufacturing and characterization of continuous carbon fiber reinforced polyphenylene sulfide filaments via melt impregnation method

Manufacturing and characterization of continuous carbon fiber reinforced polyphenylene sulfide filaments via melt impregnation method

Driving sustainability and performance: 3D-printing of lightweight functional components using recycled carbon fiber reinforced polyphenylene sulfide composites for automotive industry

Driving sustainability and performance: 3D-printing of lightweight functional components using recycled carbon fiber reinforced polyphenylene sulfide composites for automotive industry

The influence of sizing treatment on the mechanical and morphological properties of carbon fiber reinforced polyphenylene sulfide composites

AbstractCarbon fiber reinforced thermoplastics (CFRTPs) demonstrate promising applications in engineering sectors, and the interfacial interaction between CFs and the matrix plays a significant role in determining the properties of CFRPs. This work attempted to study the influence of sizing agent on the properties of polyphenylene sulfide/CF (PPS/CF) composites with an aim to fabricate PPS/CF composites with enhanced mechanical properties. The results showed that the use of 2 wt% boron phenolic resin as the sizing agent favored the formation of a uniform interfacial layer on the surface of CFs. Contact angle tests revealed that corresponding sized CFs exhibited the smallest contact angle and the highest surface energy among the studied systems. As a result, the sizing agents acted as a protective layer for CFs during melt processing process, which mitigated the damage to the CFs. The average length of CFs was longer after melt extrusion process which was vital for achieving high mechanical performance of PPS/CF composites.Highlights Coating sizing agent protected CFs from being fractured during melt processing. Applying 2 wt% BPR sizing agent yielded the best interfacial performance. The tensile strength and Yong's modulus of PPS/CFB2 reached as high as 155.9 and 7618.21 MPa. The tensile fracture mode between BPR‐treated CFs and PPS was cohesive damage.

Temporal spatial transfer characteristics and cross-scale fusion behavior mechanism of interface temperature in induction welding of plain carbon fiber polyphenylene sulfide

The intricate multiphysics coupling conditions and nonlinear characteristics inherent in carbon fiber composite induction welding render the temperature transfer properties of the interface and the fusion connection mechanism across different scales ambiguous. In this study, a transient 3D finite element model was developed to simulate the induction welding process of carbon fiber reinforced polyphenylene sulfide (CF/PPS) composites, utilizing an electromagnetic-thermal multiphysics coupling mechanism. This investigation revealed that the electromagnetic effect leads to the accumulation of magnetic flux and spatial constraints, thereby triggering an eddy current concentration effect at the interface, which serves as an additional influencing factor in induction welding's edge effect. Simultaneously, the temperature distribution at the induction welding interface exhibits a gradient characteristic over both time and space: fluctuations in the current heat source result in a pronounced gradient distribution pattern of 225 %-680 % in welding interface temperature differences, accompanied by a 43.29 % reduction in shear strength. Notably, this study delves into the intricate origin of the induction welding heat source, elucidating that the generation of induced current in the magnetic field by carbon fiber overlap contributes to volumetric heat induction. This facilitates the welding process to some extent, despite the significantly lower heat contribution compared to thermally conductive wire meshes. In conclusion, to gain deeper insights into the impact of heat input on the fusion behavior of the bonding interface, SEM analysis was conducted on the experimental samples to examine the fusion morphology of the induction welding interface. Additionally, the method of EDS elemental analysis has also been used to investigate the generation and fusion mechanisms of welding defects. The amalgamation of numerical simulation technology and multi-scale material characterization serves as a methodological guide for researching the welding mechanisms of composite materials and even extends to investigations within the domain of metal connections. Furthermore, it paves the way for exploring a multidimensional research horizon in the realm of material joining and molding.

Feasibility study of friction stir joining of aluminium with carbon fibre reinforced thermoplastic composite

During the last decades, environmental concerns and limited resources have set focus of research on lightweight, mechanically high-performing structures for the transportation industry, in order to reduce fuel consumptions and CO2 emissions. Friction Stir Joining (FSJ), as a variant of the Friction Stir Welding (FSW), is an innovative friction-based joining technique for metal-composite hybrid structures. Joining in the plasticized state below the melting temperature of the metal leads to a comparatively small heat-affected zone, so that only minor metallurgical changes occur. Additionally, only a short processing time and no additional weight in form of fasteners is needed. The main objective of this study is to evaluate the feasibility of metal-composite structures via FSJ, intending to enable a macro-mechanical interlocking bonding mechanism. Main focus was given to the integration of an aluminium nub inserted in a carbon fiber-reinforced polyphenylene sulfide (CF-PPS) sheet, to ensure sufficient plasticization of the aluminium part and no degradation in the polymer part. Residual stress arising from the friction stir joining process was also characterised using the Contour method. In this study, aluminium alloy 6082-T6 and CF-PPS composite sheets were used to produce long lap joints. Results have shown that the joints were created at almost constant peak temperature slightly above the melting temperature of the PPS but no physical-chemical changes were detected in the PPS. In addition, the influence of a PPS film as interlayer between the sheets was investigated in order to explore a method for preventing galvanic corrosion. Preliminary results indicate that it is not possible to integrate a metal nub to the CF-PPS without interrupting the PPS film. However, it is possible to create a nub within the PPS film.

Response Surface Methodology Optimization of Resistance Welding Process for Unidirectional Carbon Fiber/PPS Composites.

The use of thermoplastic composites (TPCs) as one of the lightweight solutions will inevitably encounter problems in connection. Resistance welding has the characteristics of high strength, simplicity, and high reliability, and is considered a very potential hot-melt connection technology. The resistance welding technology of unidirectional carbon fiber-reinforced polyphenylene sulfide composites (UCF/PPS) was systematically studied. The experimental results show that the 100-mesh brass mesh has the best resin wetting effect and heating efficiency, and the PPS/oxidized 100-mesh brass mesh composite resistance element (Ox-RE/PPS) has the highest welding strength. The welding failure mode changes from interface failure and RE failure to interlayer structure damage and fiber fracture. The single-factor experimental results show that the maximum welding strength is reached at 310 °C, 1.15 MPa, and 120 kW/m2. According to the conclusion of the single-factor experiment, the Box-Behnken method was further used to design a three-factor, three-level experiment, and a quadratic regression model was established according to the test results. The results of variance analysis, fitting curve analysis, and perturbation plot analysis proved that the model had high fitting and prediction abilities. From the 3D surface diagram analysis, the influence of power density is the largest, and the interaction between welding temperature and power density is the most significant. Combined with the analysis of Design Expert 13 software, the optimal range of process parameters was obtained as follows: welding temperature 313-314 °C, welding pressure 1.04-1.2 MPa, and power density 124-128 kW/m2. The average strength of resistance welding joints prepared in the optimal range of process parameters was 13.58 MPa.

Thermal decomposition study of carbon fiber-reinforced polyphenylene sulfide at high heating rates met under fire exposure

Thermal decomposition study of carbon fiber-reinforced polyphenylene sulfide at high heating rates met under fire exposure

Additive Manufacturing of Composite Polymers: Thermomechanical FEA and Experimental Study.

This study presents a comprehensive approach for simulating the additive manufacturing process of semi-crystalline composite polymers using Fused Deposition Modeling (FDM). By combining thermomechanical Finite Element Analysis (FEA) with experimental validation, our main objective is to comprehend and model the complex behaviors of 50 wt.% carbon fiber-reinforced Polyphenylene Sulfide (CF PPS) during FDM printing. The simulations of the FDM process encompass various theoretical aspects, including heat transfer, orthotropic thermal properties, thermal dissipation mechanisms, polymer crystallization, anisotropic viscoelasticity, and material shrinkage. We utilize Abaqus user subroutines such as UMATHT for thermal orthotropic constitutive behavior, UEPACTIVATIONVOL for progressive activation of elements, and ORIENT for material orientation. Mechanical behavior is characterized using a Maxwell model for viscoelastic materials, incorporating a dual non-isothermal crystallization kinetics model within the UMAT subroutine. Our approach is validated by comparing nodal temperature distributions obtained from both the Abaqus built-in AM Modeler and our user subroutines, showing close agreement and demonstrating the effectiveness of our simulation methods. Experimental verification further confirms the accuracy of our simulation techniques. The mechanical analysis investigates residual stresses and distortions, with particular emphasis on the critical transverse in-plane stress component. This study offers valuable insights into accurately simulating thermomechanical behaviors in additive manufacturing of composite polymers.

Carbon Fiber Polymer Reinforced 3D Printed Composites for Centrifugal Pump Impeller Manufacturing

Centrifugal pumps are used extensively in various everyday applications. The occurrence of corrosion phenomena during operation often leads to the failure of a pump’s operating components, such as the impeller. The present research study examines the utilization of composite materials for fabricating centrifugal pump components using additive manufacturing as an effort to fabricate corrosion resistant parts. To achieve the latter two nanocomposite materials, carbon fiber reinforced polyamide and carbon fiber reinforced polyphenylene sulfide were compared with two metal alloys, cast iron and brass, which are currently used in pump impeller manufacturing. The mechanical properties of the materials are extracted by performing a series of experiments, such as uniaxial tensile tests, nanoindentation and scanning electron microscope (SEM) examination of the specimen’s fracture area. Then, computational fluid dynamics (CFD) analysis is performed using various impeller designs to determine the fluid pressure exerted on the impeller’s geometry during its operation. Finally, the maximum power rating of an impeller that can be made from such composites will be determined using a static finite element model (FEM). The FEM static model is developed by integrating the data collected from the experiments with the results obtained from the CFD analysis. The current research work shows that nanocomposites can potentially be used for developing impellers with rated power of up to 9.41 kW.

Fatigue resistance of carbon fiber/polyphenylene sulfide composites engineered for automotive use

AbstractThis study comprehensively investigates a carbon fiber‐reinforced polyphenylene sulfide (CF/PPS) composite through tensile, fatigue, interlaminar shear strength (ILSS), dynamic mechanical tests (DMA), and also fractographic analysis. Prepared via hot compression molding, the CF/PPS composites exhibit a consistent quality. Tensile tests show an elastic modulus of 37.2 ± 0.2 GPa and an average tensile strength of 800 ± 73 MPa. Fatigue tests demonstrate infinite life at 1 million cycles, achieved at 80% of the maximum stress level. Fractographic analyses unveil directly attributable fiber failures (DAFFs), affirming a robust fiber/matrix interface. DMA shows a glass transition temperature of 86°C, showcasing the composite's structural integrity across varied temperatures. With an ILSS of 68.8 ± 3.5 MPa, the composite displays excellent fiber‐matrix adhesion. The results highlight the suitability of the CF/PPS composite for high‐strength and lightweight applications in the automotive sector, offering valuable insights for material selection, design, and production processes. Thus, contributing to the production of durable and efficient automotive components among the challenges of modern and safe transportation.Highlights Comprehensive study on CF/PPS composites. Varied mechanical assessments: tensile, fatigue, ILSS, DMA. Uniform preparation via hot compression molding. Detailed fractography reveals a strong fiber/matrix interface. Suitability for high‐strength and lightweight automotive applications.

The Influence of Thermal Parameters on the Self-Nucleation Behavior of Polyphenylene Sulfide (PPS) during Secondary Thermoforming.

During the secondary thermoforming of carbon fiber-reinforced polyphenylene sulfide (CF/PPS) composites, a vital material for the aerospace field, varied thermal parameters profoundly influence the crystallization behavior of the PPS matrix. Notably, PPS exhibits a distinctive self-nucleation (SN) behavior during repeated thermal cycles. This behavior not only affects its crystallization but also impacts the processing and mechanical properties of PPS and CF/PPS composites. In this article, the effects of various parameters on the SN and non-isothermal crystallization behavior of PPS during two thermal cycles were systematically investigated by differential scanning calorimetry. It was found that the SN behavior was not affected by the cooling rate in the second thermal cycle. Furthermore, the lamellar annealing resulting from the heating process in both thermal cycles affected the temperature range for forming the special SN domain, because of the refined lamellar structure, and expelled various defects. Finally, this study indicated that to control the strong melt memory effect in the first thermal cycle, both the heating rate and processing melt temperature need to be controlled simultaneously. This work reveals that through collaborative control of these parameters, the crystalline morphology, crystallization temperature and crystallization rate in two thermal cycles are controlled. Furthermore, it presents a new perspective for controlling the crystallization behavior of the thermoplastic composite matrix during the secondary thermoforming process.

Processing and characterization of high-performance thermoplastic composites manufactured by laser-assisted automated fiber placement in-situ consolidation and hot-press

Due to the short dwell time of processing temperature and pressure, the quality of the composite manufactured by AFP was not equal to the traditional processing method like autoclave or hot-press. Deeply understanding the mechanism of differences was conducive to improving the performance of the composite manufactured by AFP. In this study, the properties of high-performance carbon fiber reinforced polyphenylene sulfide (CF/PPS) thermoplastic composites manufactured by laser-assisted automated fiber placement (LAFP) in-situ consolidation and hot-press was characterized and compared. The temperature history of LAFP in situ consolidation indicated that the heating and cooling process occurred during a few seconds. And the crystallinity was only 21.6% for the laminate from LATP, while the void content was 2.75%. Due to the low crystallinity, high void content and low interlaminar bonding, the ILSS of the laminate from LAFP in situ consolidation was 34.9% lower than that of hot-press. However, the mode Ⅰ fracture toughness was 103.7% higher than hot-press.

Optimizing the buckling resistance of injection molding composite plates by manipulating gate locations

In contrast to continuous-fiber-reinforced polymer (cFRP), the random distribution of fibers in short-fiber-reinforced polymer (sFRP), which depends on the manufacturing process, has a significant impact on the mechanical properties of sFRP components. In this study, an automatic joint injection-buckling analysis framework was developed that can simulate the injection process and predict the mechanical performance in sequence. This automatic analysis framework can be directly utilized to optimize the manufacturing process to improve mechanical properties. Based on this method, it is demonstrated that an sFRP plate (consisting of carbon fiber-reinforced polyphenylene sulfide) has better buckling resistance than an aluminum alloy plate with the same design weight. The buckling resistance can be further improved by manipulating the gate location in the injection molds. The optimization scheme was verified using the conventional analysis framework. Moreover, the optimization method was improved by utilizing a tensor-similarity-based algorithm, which can substantially decrease the time required to locate the optimal solution.

Refill friction stir spot welding of thermoplastic composites: Case study on Carbon-fiber-reinforced polyphenylene sulfide

Refill Friction Stir Spot Welding (refill FSSW) is an innovative solid-state welding technique that has been successfully applied to various combinations of metallic materials. The objective of the present study is to investigate the feasibility of refill FSSW for polymer–polymer structures, with a specific emphasis on carbon-fiber-reinforced polyphenylene sulfide (CF-PPS). The influence of the key joining parameters, i.e. force, plunge depth, rotational speed, and tool diameter, has been analyzed in terms of the resulting joint microstructure, mechanical strength, and failure mechanisms. The lap shear tests revealed two primary failure modes: interfacial shear failure and nugget pull-out. Fracture surfaces exhibited broken fibers. The depth of the joint was found to play a crucial role in determining the failure mode, with interfacial shear failure resulting in higher lap shear strength. Thermal analyses conducted on the produced joints showed no evidence of thermal degradation, which aligns with the temperature measurements during the process, as they remained below the melting temperature of CF-PPS.

Effects of thermal process conditions on crystallinity and mechanical properties in material extrusion additive manufacturing of discontinuous carbon fibre reinforced polyphenylene sulphide composites

This study investigates the thermal behaviour of discontinuous carbon fibre reinforced polyphenylene sulphide (CF/PPS), additively manufactured by material extrusion, with a focus on the effects of thermal process conditions on the degree of crystallinity, oxidation crosslinking and mechanical properties of CF/PPS from filament fabrication, material extrusion to annealing treatment. The screw extrusion parameters are optimised by performing a thermal analysis of the fabricated filaments. The effect of crosslinking reactions on the crystallinity process in determining the mechanical properties of the printed samples is illustrated by investigating the influence of the printing conditions. Furthermore, the effect of annealing treatment on the semi-crystalline polyphenylene sulphide (PPS) is studied by measuring the degree of crystallinity and viscoelasticity behaviours. Results demonstrate that the flexural properties of the printed CF/PPS composites at elevated processing temperatures are determined by the oxidation crosslinking between PPS chains. These enhance the crystallisation process of semi-crystalline polymers by acting as the nucleating agent first but negatively affect the mechanical properties at higher temperatures because of the detrimental effects of the polymer inter-chain bonding. The maximum flexural strength of printed CF/PPS reached 164.65 MPa when processing at an extrusion temperature of 280°C, a printing temperature of 320°C, and an annealing temperature of 130°C for 6 h. By adjusting the thermal treatment conditions, the degree of the crystallinity and the mechanical properties of the printed CF/PPS composites can be designed, controlled and tailored.

Enhancement of interfacial properties of carbon fiber reinforced polyphenylene sulfide resin by sulfur treatment

AbstractThe properties of carbon fiber (CF) reinforced thermoplastic resin composites depend on the physical and chemical interaction between the fibers and the resins. However, surface oxidation is not always necessary. In this study, the interaction between CF and Polyphenylene sulfide (PPS) is enhanced by using an emulsion of reactive sulfur to treat the CF surface. The interlaminar shear strength (ILSS) of CF/PPS composites is experimentally investigated and found to be up to 79.7 MPa, an increase of 36.1% compared to the untreated CF. The enhancement mechanism of the modification method established is inferred. Scanning electron microscope (SEM) and X‐ray photoelectron spectroscopy (XPS) results showed that sulfur etching on the surface of CF generated new functional groups, which improved the interfacial effect, and tightened the bond between CF and PPS. This indicates that sulfur treatment along with sizing must be a simpler method than surface oxidation to promote the interfacial bonding between CF and PPS.

Applicability assessment of thermoset coating onto additively manufactured thermoplastic composite molds

Coatings can significantly enhance the surface characteristics of printed molds however, there is no guideline to assess the coating applicability for additively manufactured fiber-reinforced thermoplastic molds. Therefore, the applicability of a thermoset polymer surface coating onto additively manufactured carbon fiber-reinforced Polyphenylene Sulfide (CF-PPS) composite mold was investigated. The coating application temperature should not be higher than the maximum operable temperature of the substrate. Therefore, Dynamic Mechanical Analysis (DMA) of the printed CF-PPS was performed to characterize the dependence of the elastic modulus on temperature as well as to verify the thermal stability of the printed molds at the coating processing temperature. The cure kinetics of the coating material was characterized to guide the design of processing conditions to achieve a complete cure of the thermoset resin. The composite mold needs to withstand multiple thermal cycles for the part manufacturing process. Thermal degradation of the coating was assessed for multiple thermal cycles utilizing Thermogravimetric Analysis (TGA) and the results did not show significant degradation. To provide insights into the coefficient of thermal expansion (CTE) mismatch between the coating and the printed CF-PPS, the CTE was characterized for both material systems. Additionally, the coating adhesion was characterized via pull-off tests after multiple thermal cycles and the results revealed no significant change in the pull-off strength after ten cycles. Finally, the coating was demonstrated on a mold printed with CF-PPS which was subjected to multiple autoclave composite part manufacturing cycles. The durability of the coating and the geometrical deviation of the mold were investigated throughout the manufacturing cycles.

A water-soluble PAAs sizing agent for enhancing interfacial adhesion of carbon fiber reinforced polyphenylene sulfide composites (CF/PPS)

Due to low activity and poor wettability of carbon fiber (CF), the interaction between CF and polyphenylene sulfide (PPS) matrix is weak, which decreases the mechanical properties of CF reinforced PPS （CF/PPS） composites. In this article, the interfacial adhesion of CF/PPS composites was strengthened by using a water-soluble poly (amic acid) ammonium salt (PAAs) as sizing agent. This PAAs-based sizing agent had good compatibility with PPS and formed hydrogen bonds with CF activated by Meldrum’s acid. Significantly, the PAAs sizing agent can be soluble in water (up to 20 wt % high solid content) without organic solvents and surfactants, which shows huge potential in industrial applications. Experimental results demonstrated that the interlaminar shear strength (ILSS), flexural strengths, and moduli of modified CF/PPS composites increased by 19.5%, 24.9%, and 10.1%, respectively. According to the SEM images on fractured surfaces of composites, fiber and PPS resin were tightly packed, and the failure mechanism was interface deformation or resin breakage.