Fiber-reinforced Thermoplastics Research Articles

Effect of Carbon Nanofiber Distribution on Mechanical Properties of Injection-Molded Aramid-Fiber-Reinforced Polypropylene.

The mechanical recycling of discarded plastic products as resources for environmental preservation has recently gained research attention. In this context, it is necessary to use waste materials for fiber-reinforced thermoplastics (FRTP). Glass and carbon fibers are often damaged by shear and compression during melt-forming processes. To achieve a sustainable society, it is necessary for thermal recycling to produce minimal to no residue and for mechanical recycling to maintain the length of fibers used in FRTP to preserve their performance as a reinforcing agent. Aramid fibers (AFs) do not shorten during the melt-molding process, and their composites have excellent impact strength. On the other hand, plastics reinforced with glass or carbon fibers are reported to have a superior strength and modulus of elasticity compared to aramid fibers. This study investigates the dispersion of a carbon nanofiber (CNF), a whisker, as the third component in aramid-fiber-reinforced polypropylene (PP/AF). The results and discussion sections demonstrate how the dispersion of CNF in PP/AF can enhance the mechanical properties of injection-molded products without compromising their impact resistance. The proposed composition will have excellent material recyclability and initial mechanical properties compared to glass-fiber-reinforced thermoplastics.

Local thermal non-equilibrium effects on phase transition of fiber reinforced thermoplastic composites with temperature-dependent heat generation

Under the excitation of external fields, fiber reinforced thermoplastic (FRTP) composites can be thermally processed due to the internal heat generation, in which the local thermal non-equilibrium (LTNE) can be significant during the phase transition. In this study, a representative elementary volume scale Lattice Boltzmann model was developed to simulate the phase transition process of FRTP composites with the temperature-dependent internal heat source. The results from LTNE model and local thermal equilibrium (LTE) model were compared in terms of the phase interface evolution and the local temperature difference between fibers and matrix, so that the LTNE effects on phase transition behaviors were examined with different material properties and internal heat sources. It is found that the LTNE effects cannot be ignored in FRTP composites, and the main mechanisms include the dynamic local heat generation, endothermic phase transition of matrix, and relatively high thermal conductivity of fiber. A small heat exchange between the fibers and matrix results in a large local temperature difference and a slow phase transition. A high internal heat generation enhances the phase transition and LTNE effects, but an increase in the temperature range for heat generation leads to a slow phase transition with slight change in LTNE effects. With the increase of matrix fraction, LTNE effects first increase and then decrease due to the combined results of the more internal heat generation and the increase of endothermic mass of matrix and the less heat loss through fibers. This study is significant for guiding the reliable thermal processing of FRTP composites in emerging industrial applications.

Ultrasonic welding of CF/PA6 composite to 6061Al alloy utilizing an interfacial coating as energy director

This study investigates ultrasonic plastic welding to join the carbon fiber-reinforced thermoplastics and 6061Al alloy in a lap-type joint configuration. An interfacial polymer coating through a fluidized bed on aluminum alloy was considered an energy director, as it was essential for concentrating heat at the interface during welding. The significant ultrasonic process setting (weld pressure: 0.5 MPa, weld time: 600 ms, hold time: 1000 ms) was statistically realized for a maximum lap shear strength of the joint that showed the interlaminar shear (first-layer ply) failure of the composite, while the welding interface morphology revealed interdiffusion of thermoplastics with the load-bearing carbon fibers attached to the composite-coating resin mixtures, whereas the coating interface offered a strong adhesion of polymer on the aluminum surface asperities through mechanical interlocking. An efficient multi-material joint was obtained within 1.6 s in comparison to the adhesive bonding technology that required at least 20 min. Additionally, the interfacial coating serves as an insulator, avoiding galvanic corrosion in joints as well as fretting damage. The encouraging findings of this research provide deeper insight into joining thermoplastic composites to metals by ultrasonic plastic welding without the use of a separate energy director, which simplifies the process of industrialization.

On the effectiveness of deep material networks for the multi-scale virtual characterization of short fiber-reinforced thermoplastics under highly nonlinear load cases

A key challenge for the virtual characterization of components manufactured using short fiber-reinforced thermoplastics (SFRTs) is the inherent anisotropy which stems from the manufacturing process. To address this, a multi-scale approach is necessary, leveraging deep material networks (DMNs) as a micromechanical surrogate, for a one-stop solution when simulating SFRTs under highly nonlinear long-term load cases like creep and fatigue. Therefore, we extend the a priori fiber orientation tensor interpolation for quasi-static loading (Liu et al. in Intelligent multi-scale simulation based on process-guided composite database. arXiv:2003.09491, 2020; Gajek et al. in Comput Methods Appl Mech Eng 384:113,952, 2021; Meyer et al. in Compos Part B Eng 110,380, 2022) using DMNs with a posteriori approach. We also use the trained DMN framework to simulate the stiffness degradation under fatigue loading with a linear fatigue-damage law for the matrix. We evaluate the effectiveness of the interpolation approach for a variety of load classes using a dedicated fully coupled plasticity and creep model for the polymer matrix. The proposed methodology is validated through comparison with composite experiments, revealing the limitations of the linear fatigue-damage law. Therefore, we introduce a new power-law fatigue-damage model for the matrix in the micro-scale, leveraging the quasi-model-free nature of the DMN, i.e., it models the microstructure independent of the material models attached to the constituents of the microstructure. The DMN framework is shown to effectively extend material models and inversely identify model parameters based on composite experiments for all possible orientation states and variety of material models.

Effect of thermal-mechanical conditions on strength of silanized Al alloy/CFRTP hybrid joint made by thinning-controlled hot pressing

The strength of thermal-assisted joined metal and carbon fiber-reinforced thermoplastics (CFRTP) is dependent on physical and chemical interactions at the joining interface, which are strongly influenced by heat and pressure. Currently, there is a lack in deep research on effect mechanism of changeable pressure on the joining quality, limiting the joining condition optimization of the thermal-assisted joining process. In this study, an improved hot-pressing joining process with added thinning displacement control was adopted to study the effect of the joining pressure on the structure and strength of the interface between a silane-treated Al alloy and three CF-Polyamide-6 (CF/PA6). A high-strength, thinning-controlled lapped joint of Al and CF/PA6 could be realized by the proposed process, regardless of the fiber volume fractions in CF/PA6. At temperatures above the melting point of PA6, higher pressure typically resulted in higher interface strength. However, as the temperature approached the decomposition temperature, the joints under higher pressure tended to exhibit lower strength. The underlying mechanism of the interface strength variation with pressure was investigated by analyzing the effects of the joining conditions on the chemical reaction conditions, the resolidified-resin structure near the interlayer, and the existence of defects. These findings lay the foundational groundwork for future endeavors in metal/composite joining, offering potential benefits for industrial applications and environmental sustainability in the automotive sector.

Characterization and prediction of tensile properties of carbon fiber-reinforced thermoplastics composed of hybrid short carbon fiber/PA6 fiber nonwoven mats

Hybrid carbon fiber/resin fiber nonwoven mats are considered as a highly promising application of recycled carbon fibers due to their low cost and simple synthesis process. However, the mechanical properties of hybrid nonwoven mats are subject to uncertainties due to nonuniformity of fiber orientations during production procedures, which restricts their use in structural components. This study investigates the characteristics of various types of hybrid nonwoven mats with different volume fractions and fiber orientation distributions. Notably, the investigation yields noteworthy tensile properties, exemplified by a tensile strength of 367.20 MPa and a stiffness of 32.85 GPa, when the volume fraction is 28.9%. Tensile properties of the hybrid nonwoven mats and their fluctuations are then analyzed through statistical analyses. A three-dimensional microstructure-based fiber network model is established using the Monte Carlo method to represent the statistical and stochastic properties of the material. Furthermore, a prediction method of tensile properties based on microstructural properties in the model is proposed, which shows good agreement with all experimental results for adjustments of the volume fraction of carbon fibers, distribution of fiber lengths, and anisotropy of the materials, significantly reducing the experimental burden for optimization research. The tensile characteristics of composites are reliably anticipated with a nominal error margin below 10%. Additionally, this prediction method enables the prediction of scatter and stable standard deviation, making it possible to apply hybrid nonwoven mats in recycling and industrial processes.

3D Printing Techniques for Enhancing Mechanical Properties of Continuous Carbon Fiber-Reinforced Thermoplastics

3D Printing Techniques for Enhancing Mechanical Properties of Continuous Carbon Fiber-Reinforced Thermoplastics

Modeling of a Process Window for Tailored Reinforcements in Overmolding Processes

This study explores cost-effective and customized composite applications by strategically placing carbon fiber-reinforced thermoplastics in multi-material designs. The focus is on developing a model for the simultaneous processing of non-reinforced and reinforced thermoplastic layers, with the aim of identifying essential parameters to minimize insert flow and ensure desired fiber orientation and positional integrity. The analysis involves an analytical solution for two layered power-law fluids in a squeeze flow setup, aiming to model the combined flow behavior of Newtonian and pseudo-plastic fluids, highlighting the impact of the non-Newtonian nature. The behavior reveals a non-linear trend in the radial flow ratio towards the logarithmic consistency index ratio compared to a linear trend for Newtonian fluids. While a plateau regime of consistency index ratios presents challenges in flow reduction for both layers, exceeding this ratio, depending on the height ratio of the layers, enables a viable overmolding process. Therefore, attention is required when selectively placing tailored composites with long-fiber-reinforced thermoplastics or unidirectional reinforcements to avoid operating in the plateau region, which can be managed through appropriate cavity or tool designs.

Enhancing the Design of Experiments on the Fatigue Life Characterisation of Fibre-Reinforced Plastics by Incorporating Artificial Neural Networks.

Fatigue life testing is a complex and costly matter, especially in the case of fibre-reinforced thermoplastics, where other parameters in addition to force alone must be taken into account. The number of tests required therefore increases significantly, especially if the influence of different fibre orientations is to be taken into account. It is therefore important to gain the greatest possible amount of knowledge from the limited number of available tests. In order to achieve this, this study aims to utilise adaptive sampling, which is used in numerous areas of computational engineering, for the design of experiments on fatigue life testing. Artificial neural networks (ANNs) are therefore trained on data for the short-fibre-reinforced material PBT GF30, and their areas of greatest model uncertainty are queried. This was undertaken with ANNs from various numbers of hidden layers, which were analysed for their performance. The ideal case turned out to be four hidden layers, for which a squared error as small as 1 × 10-3 was recorded. Locally resolved, the ANN was used to identify the region of greatest uncertainty for samples of vertical orientation and small numbers of cycles. With information such as this, additional data can be obtained in such uncertain regions in order to improve the model prediction-almost halving the recorded error to only 0.55 × 10-3. In this way, a model of comparable value can be found with less experimental effort, or a model of better quality can be set up with the same experimental effort.

Biaxial fatigue failure of short glass fiber reinforced polyamide 6,6: An in-depth investigation of stiffness drop and microstructural evolution

In the automotive industry, short glass fiber-reinforced thermoplastics are widely used under the hood and subjected to dynamic vibrations of the engine in multiple directions resulting in fatigue failure. Under fatigue loading, a significant portion of the strain energy is stored within the material, while the remaining portion is lost due to internal frictions and the damage occurrence. Internal friction results in heat generation, which in turn causes an increase in external temperature. This increase in temperature leads to thermal degradation of the polymer. Investigations on the cause of the stiffness drop are not widely available in the literature. Therefore, this study explores the source of the stiffness drop under biaxial fatigue loading of a polyamide 6,6 reinforced with 30 wt. % short glass fibers (PA66GF30) and distinguishes the contributions of thermal degradation and damage accumulation. The thermal evolution of the specimens was captured by means of thermography. In addition, the digital image correlation (DIC) technique was used to measure the in situ strain field during the fatigue. Despite the temperature stabilization being observed around the 10,000th cycle, the reduction in the stiffness continued until failure which was attributed to the mechanical damage accumulation and cyclic creep during the fatigue tests. Dynamic mechanical analyses (DMA) were carried out to quantify the stiffness drop with the varying temperature. From the results, it is seen that the damage accumulation and cyclic creep during the fatigue tests were responsible for the major part of the stiffness drop. Finally, scanning electron microscopy (SEM) inspection of the fracture surface was performed to identify fatigue damage mechanisms. Four unique features associated with the fatigue damage were identified: (1) debonding of fibers from the matrix, (2) polymer matrix crazing, and (3) cavitation and porosities, (4) pull out fiber ends and break on the fiber.

Investigation of bio-based and recycled printing materials for additive manufacturing

Additive manufacturing (AM) processes are becoming increasingly important alongside conventional processes. As a result, the consumption of materials is also increasing. The most widespread process in polymer AM is Fused Layer Modelling (FLM). Today, the FDM process often uses synthetically produced materials based on petrochemical processes. However, there is little knowledge about which bio-based and recycled polymer materials are suitable for sustainable polymer AM. The aim of this paper is to carry out investigations of eight selected materials, which are already commercially available, to gain insights into their suitability as materials for polymer AM. These materials are divided into four categories: conventional, recycled, bio-based and fibre-reinforced thermoplastics. The evaluation model consists of a point system in which the materials are evaluated according to various weighted criteria. For technical, economic and ecological evaluation meaningful criterions were developed and applied. Based on the evaluations, three two-dimensional strength diagrams were developed, from which the results of the materials, on two of the evaluations in each case, can be read. These results are combined in a three-dimensional diagram. This representation provides the ability to make a precise selection of bio-based or recycled materials for polymer AM.

Effects of the Injection Material and Resin Layer on the Mechanical Properties of Carbon Fiber-Reinforced Thermoplastic (CFRTP) Press and Injection Hybrid Molded Parts

In the press and injection hybrid molded parts of fiber-reinforced thermoplastics (FRTPs), failure at the interface between the surface material (the outer shell) and the ribs (the injection part) or that at the injection part has become an issue. Adding a resin layer to the rib roots at the same time that the ribs are molded through injection has been proposed, which may increase the mechanical properties and reduce the material cost. To prevent failure at the injection part, the use of fiber-reinforced resin as an injection material has been suggested. This approach contributes to a higher bond strength by lowering the molding shrinkage rate. In this study, the hat-shaped parts of carbon fiber-reinforced thermoplastics (CFRTPs) with fiber-reinforced and neat resin layers at the rib root were fabricated through press and injection hybrid molding, and their mechanical properties were evaluated through three-point bending tests. The effects of the resin layer at the rib root and the existence or nonexistence of fiber reinforcement on the mechanical properties, as well as the relationship between the material cost and the mechanical properties, were clarified through an experiment and FEM analysis. The bond strength was also evaluated through tensile tests that were undertaken at the rib root. Molded parts with neat PA6 and glass fiber-reinforced PA6 resin layers at the rib roots showed higher bond strength than those without resin layers. In a three-point bending test of a CFRTP hat-shaped part with a resin layer at the rib roots, the use of a 1 mm thick CFRTP laminate for the outer shell and glass fiber-reinforced PA6 resin as the injection material showed the same stiffness as a part that used a 2 mm thick CFRTP laminate for the outer shell. FEM analysis showed that the resin layer prevented the concentration of strain at the rib roots, and the model that used a 1 mm thick CFRTP laminate for the outer shell and glass fiber-reinforced PA6 resin as the injection material showed the best specific stiffness in this study. By adding a resin layer to the rib roots, the fabrication of molded parts with excellent specific stiffness was enabled at a small increase in cost.

Effects of Process Parameters in Thermoforming of Unidirectional Fibre-Reinforced Thermoplastics.

Process-induced defects during thermoforming are widespread problems in laminate manufacturing. The aim of this study is to describe the effects of holding time and pressure on several properties of the manufactured laminate. A design of experiments is performed, followed by an analysis of variance to examine significant effects. Subsequently, a regression model is created to predict the laminate's properties, which is also validated. A significant interaction between holding time and pressure is determined for the resulting tensile strength and elongation at break with a p-value of 1.52·10-16 and 0.02, respectively. The highest values of tensile strength and elongation at break are found for low settings of holding time and pressure. The fibre volume fraction is not affected by the process parameters. As holding time and pressure increase, significant fibre misalignment takes place, leading to a decrease of the mechanical properties. The regression model corresponds well with the validation and a tensile strength of 1049 MPa with an elongation at break of 2.3% is reached.

Evaluation of True Bonding Strength for Adhesive Bonded Carbon Fiber-Reinforced Plastics.

Carbon fiber-reinforced thermoplastics (CFRTPs) have attracted attention in aerospace because of their superior specific strength and stiffness. It can be assembled by adhesive bonding; however, the existing evaluation of bonding strength is inadequate. For example, in a single-lap shear test, the weld zone fails in a combined stress state because of the bending moment. Therefore, the strength obtained experimentally is only the apparent strength. The true bonding strength was obtained via numerical analysis by outputting the local stress state at the initiation point of failure. In this study, the apparent and true bonding strengths were compared with respect to three types of strength evaluation tests to comprehensively evaluate bonding strength. Consequently, the single-lap shear test underestimates the apparent bonding strength by less than 14% of the true bonding strength. This indicates that care should be taken when determining the adhesion properties for use in numerical analyses based on experimental results. We also discussed the thickness dependence of the adhesive on the stress state and found that the developed shear test by compression reduced the discrepancy between apparent and true strength compared with the single-lap shear test and reduced the thickness dependence compared with the flatwise tensile test.

The mechanics of thin elastic sheet reinforced with fiber mesh subjected to combined flexure and extension

We present a three-dimensional continuum model aimed at investigating the mechanical performance of elastomeric materials reinforced with bidirectional fibers undergoing the combined out-of-plane bending moment and bilateral extension. To achieve this, we consider the Neo-Hookean strain energy model for the matrix material of the fiber composite and incorporate the strain energy of bidirectional fibers into the strain energy potential of the fiber composite. The bidirectional fibers’ strain energy is rigorously modeled by configuring the fiber kinematics on the fiber composite surface using differential geometry and accounting for stretching, bending, and twisting responses of the fibers via the computation of the first-order and second-order gradient of deformation. To establish equilibrium equations, we apply the variational principle to derive the constitutive relations, resulting in the normal and tangential shape equations of the fiber composite, and boundary conditions of bending and stretching. The model implementation emphasizes analyzing the combined out-of-plane bending and bilateral stretching effects on the fiber composite material, and the numerical results include the out-of-plane and in-plane deformation, strain-loading responses, bending, twisting, and stretching of fibers within the matrix material, as well as the deformation of the fiber network. Specifically, it is found that a larger bending moment results in intensified out-of-plane deformation while larger bilateral stretch decreases the out-of-plane deformation of fiber composite. In particular, bilateral stretches reduce the Lagrange strain (ɛ1) near the bilateral boundaries, unlike the intensity distribution of Lagrange strain (ɛ2) maintains almost unchanged due to no external tension applied on the upper and lower boundaries of the fiber while bending moments persist. These findings highlight the role of bilateral stretching acting as the prestress in reducing deflection, enhancing tensile strength and efficient use, and controlling crack generation of fiber-reinforced polymer (FRP) composites. More importantly, despite the scarcity of experimental data on fiber composite deformation at the microscopic, the theoretical demonstration of the extension and flexure of fiber units provide reasonable explanations for the resulting deformation of the overall fiber meshwork, validating the mechanism that the fiber microstructure deformation determines the overall deformation of fiber composites when subjected to combined bending moment and tension. Special attention should be given to the potential dislocation between the embedded meshwork and matrix material located in the center of the domain. Furthermore, the proposed model provides qualitatively reasonable explanations on the shaping of Bamboo Polylactic acid (PLA) composites, out-of-plane deformation of woven fabric, Sikken-type stiffener deformation, and fiber-reinforced thermoplastics via a series of numerical results.

A new method of preparing lattice structures of continuous carbon fiber-reinforced thermoplastics

The three-dimensional lattice sandwich structure of composite has attracted extensive attention in the engineering field due to its superior mechanical property and multifunctional designability. Developing technology that can guarantee both production cycle and cost remains challenging. In this work, an innovative forming technology based on 3D printing and hot folding process is presented to fabricate lattice sandwich structures of continuous fiber-reinforced thermoplastics. The prepared lattice sandwich structures show obvious competitiveness and superior material efficiency, which is reflected in high compressive strength (23.55 MPa/(g/cm3)) and specific compressive modulus (457.82 MPa/(g/cm3)). The simplified theoretical model and 3D progressive failure model are carried out to predict the compressive behaviors of the lattice sandwich structures, and the results are consistent with the experimental results. Additionally, the flexibility of the proposed method is demonstrated by fabricating various 3D structures.

Micromechanics study of short carbon fiber-reinforced thermoplastics fabricated via 3D printing using design of experiments

In this study, short carbon fiber-reinforced thermoplastic (sCFRTP) was 3D-printed under different printing parameters, and the influence of the combination of printing parameters on the tensile properties and internal structure (void volume fraction, fiber orientation, and fiber length) of the 3D-printed sCFRTP was investigated through tensile testing, X-ray computed tomography, microscopic observations and theoretical analysis based on a micromechanics model (MM). A total of ten printings and characterizations were performed via the design of experiments, and the outcomes displayed specimens that were fabricated under optimal printing parameters (specimen DoE) exhibited a Young's modulus of 5.1 ± 0.3 GPa and a tensile strength of 73.3 ± 0.9 MPa, resulting in the highest Young's modulus and tensile strength. The MM analysis successfully reproduced the experimental stress-strain response as well as the equivalent stiffness of the sCFRTPs with a much shorter time than finite element analysis by inputting the measured fiber length, void volume fraction, and fiber orientation distribution into the in-house MM code. From this MM analysis, it was suggested the higher Young's modulus and tensile strength observed in the specimen DoE is due to more of the relatively long fibers are oriented in the print direction with fewer voids. Furthermore, the influence of internal structure parameters on the mechanical properties of the 3D-printed sCFRTPs was analyzed, revealing that fiber length has a greater impact on the mechanical properties than void volume fraction and fiber orientation distribution.

Fatigue Damage of Short Fibre-Reinforced Thermoplastics in Crashworthiness Simulation

Service loads repeatedly stress components on a regular basis and lead to fatigue damage in the material. In the case of components made of short fibre-reinforced thermoplastics, which are also crash-relevant in addition to only bearing service loads, however, a significant deterioration in mechanical properties can be observed after fatigue damage has been introduced. This is where the approach presented in this paper comes in: in order to enable a realistic simulation of such components in their used conditions, the material data are assigned depending on previously determined damage. The approach, which combines the domains of highly dynamic and cyclic experiments as well as different types of numerical simulations, is tested for its performance in the present paper. For this purpose, component tests are carried out on cross-rib beams, which serve to validate the method. The novelty and uniqueness of this paper lies in the linking of fatigue life and crashworthiness considerations for short fibre-reinforced thermoplastics, which, in this case, is raised to a new level by considering the component level for the first time.

Analysis of energy release rate of laser-induced cohesive bonding of carbon fiber-reinforced polyetherketoneketone thermoplastic composites

In this study, laser joining of carbon fiber/polyetherketoneketone composites with several patterns was investigated to achieve weight reduction without any mechanical fasteners. The laser beam concentrated the energy, and heat conduction in the through-thickness direction of heterogeneous carbon fiber-reinforced thermoplastics caused molecular diffusion at the joining interface. According to the double-beam cantilever test results, the maximum energy release rate (ERR) was 2.01 J/mm2, which was 900 % higher than that of epoxy adhesive joining using laser power densities in the range of 1.05–1.34 W/mm2. A higher ERR was achieved because the optimized laser joining pattern secured repetitive cohesive joining at the interface. Thus, a complicated and step-wise crack opening was observed, which interfered with the propagation.

Four-dimensional printing of continuous glass fiber-reinforced thermoplastics

Shape memory polymers (SMPs) are a new class of materials in which their shapes can be changed over time. Despite their lightness and ease of fabrication, SMPs have very low recovery forces and are therefore inefficient when high loads are applied. To improve the mechanical properties of polymeric materials, glass fiber (GF) is commonly used as a reinforcement. The purpose of this study was to demonstrate a four-dimensional (4D) printing process using material extrusion additive manufacturing on both polylactic acid (PLA) and thermoplastic polyurethane (TPU). The goal was to improve the recovery forces in SMPs. GF roving was fed continuously into the nozzle of a three-dimensional (3D) printer to fabricate composite specimens. Also, multi-layer PLA/TPU specimens were printed. There was a measurement of shape fixity, shape recovery, and force recovery ratios. A multi-objective function analysis was performed to determine the optimum material based on recovery force priority in this study. In terms of recovery force, GF showed a superior effect. For composite specimens, shape fixity and recovery ratios decreased and increased, respectively. According to the result of optimization, PLA with 6.62 % GF proved to be the best material. PLA's recovery force has been improved by annealing heat treatment. Furthermore, cyclic experiments up to three cycles were conducted to evaluate the performance of the optimum material.