High-performance Thermoplastics Research Articles

In-situ infrared thermography measurements to master transmission laser welding process parameters of PEKK

The temperature field along the thickness of the specimens has been measured during transmission laser welding. Polyetherketoneketone (PEKK) is a very high performance thermoplastic with tunable properties. We have shown that this grade of PEKK can be turned to quasi-amorphous or semi-crystalline material, due to its slow kinetics of crystallization. Its glass transition temperature is 150 °C. The effect of its crystalline rate directly impacts its optical properties: the transmittance of quasi-amorphous PEKK is about 60% in the NIR region (wavelength range from 0.4 to 1.2 µm) whereas it is less than 3% for the semi-crystalline material. The welding tests have been carried out with an 808 nm laser diode apparatus. The heat field is recorded during the welding experiment by infrared thermography with the camera sensor perpendicular to the lasersheet and to the sample's length to focus on the welded interface. The study is divided in two steps: firstly, a single specimen is irradiated with an energy density of 22 J.mm−²: the whole sample thickness is heated up, the maximum temperature reaches 222 ± 7 °C. This temperature corresponds to about Tg + 70 °C, but the polymer does not reach its melting temperature. After that, welding tests were performed: a transparent (quasi-amorphous) sample as the upper part and an opaque (semi-crystalline) one as the lower part were assembled in static conditions. The maximum temperature reached at the welded interface is about 295 °C when the upper specimen is irradiated for 16 s with an energy density of 28 J.mm−². The temperature at the welded interface stays above Tg during 55 s and reached the melting temperature during 5 s before rapid cooling. These parameters are suitable to assemble both polymeric parts in a strong weld. This work shows that infrared thermography is an appropriate technique to improve the reliability of laser welding process of high performance thermoplastics.

CTAB induced emission from water soluble polyarylene ether nitrile carboxylate and selective sensing of Fe (III) ions

Polyarylene ether nitrile (PEN) is traditionally used as high performance thermoplastics in various advanced engineering materials fields. However, the preparation of optically active PEN based materials, especially in aqueous solution, is still a great challenge. In this work, the side chain carboxylated PEN can be readily dissolved in alkaline solution but showing strongly quenched luminescence. Fortunately, the cationic surfactant of cetyltrimethylammonium bromide (CTAB) was able to recover the fluorescence emission of water soluble PEN, which can be subsequently quenched by Fe3+ ions, leading to the selective determination of Fe3+ ions in aqueous solution.

Gear fatigue life and thermomechanical behavior of novel green and bio-composite materials VS high-performance thermoplastics

In many applications, metal gears have been replaced by plastic gears because of their functionality and cost advantages. Despite their many benefits, the intensive use of plastics and composites raises sustainability issues because of the depletion of non-renewable petroleum resources and the pollution that is generated. Thus, alternative ecological solutions for plastic gears are necessary; however, little is known regarding ecologically designed gears. In this study, we propose two types of innovative gear materials. The first is a semi-ecological polyethylene bio-composite gear reinforced with birch fibers, and the second is a fully bio-sourced natural polyethylene gear with birch fibers. This study is the first time such fully ecological composite-plastic gears have been tested. The tests record the evolution of the fatigue and temperature over time under various operating conditions. Furthermore, acoustic emission is used to assess the evolution of fatigue cracks. The results indicate that the fully ecological gears are feasible and offer an alternative to traditional materials, such as engineering plastics, likely at a lower cost.

Fatigue life and residual strength of a short- natural-fiber-reinforced plastic vs Nylon

A new natural fiber composite made of high density polyethylene (HDPE) and short birch fibers (SBF) was developed to replace high-performance thermoplastics (Polyamide) commonly used in gears manufacturing. 3-point flexural quasi-static tests were achieved on bending specimens to assess mechanical properties. Comparison between these results and those of polyamide (PA) and neat polyethylene has showed that the polyethylene reinforced with 40%wt of SBF presents tensile and flexural mechanical properties that are higher than those of the PA11 or the neat polyethylene. After static characterisation, fatigue tests were performed to determine e-N curves and the evolution of residual strength. Then, the fatigue behavior of the studied composite has been compared with that of PA66 and of ultra-high molecular weight polyethylene (UHMWPE). It has been noticed that polyethylene reinforced with 40%wt of SBF presents a high cycle fatigue strength (HCFS) that is more important than that of PA66 and UHMWPE. Consequently, the studied composite represents a good alternative to replace Nylon in spur gears manufacturing.

Computational and experimental investigations of one-step conversion of poly(carbonate)s into value-added poly(aryl ether sulfone)s

It is estimated that ∼2.7 million tons poly(carbonate)s (PCs) are produced annually worldwide. In 2008, retailers pulled products from store shelves after reports of bisphenol A (BPA) leaching from baby bottles, reusable drink bottles, and other retail products. Since PCs are not typically recycled, a need for the repurposing of the PC waste has arisen. We report the one-step synthesis of poly(aryl ether sulfone)s (PSUs) from the depolymerization of PCs and in situ polycondensation with bis(aryl fluorides) in the presence of carbonate salts. PSUs are high-performance engineering thermoplastics that are commonly used for reverse osmosis and water purification membranes, medical equipment, as well as high temperature applications. PSUs generated through this cascade approach were isolated in high purity and yield with the expected thermal properties and represent a procedure for direct conversion of one class of polymer to another in a single step. Computational investigations performed with density functional theory predict that the carbonate salt plays two important catalytic roles in this reaction: it decomposes the PCs by nucleophilic attack, and in the subsequent polyether formation process, it promotes the reaction of phenolate dimers formed in situ with the aryl fluorides present. We envision repurposing poly(BPA carbonate) for the production of value-added polymers.

An approach towards tailoring interfacial structures and properties of multiphase renewable thermoplastics from lignin–nitrile rubber

High-performance multiphase thermoplastics were synthesized by reactive mixing of unmodified industrial lignin and low-cost additives in a matrix of general-purpose acrylonitrile-butadiene rubber (NBR).

Improvement of adhesion strength of self-adhesive silicone rubber on thermoplastic substrates – Comparison of an atmospheric pressure plasma jet (APPJ) and a Pyrosil® flame

Polymeric hard/soft combinations consisting of a rigid, thermoplastic substrate and an elastomeric component offer many advantages for plastic parts in industry. Manufactured in one step by multi-component injection moulding, the strength of the thermoplastics can be combined with sealing, damping or haptic properties of an elastomer. Bonds of self-adhesive liquid silicone rubber (LSR) on high performance thermoplastics such as polyetheretherketone (PEEK) or polyphenylene sulphide (PPS) are especially interesting e.g. for medical applications due to their outstanding resistance properties. To ensure good adhesion between the two components, surface treatments from an atmospheric pressure plasma jet (APPJ) and a Pyrosil® flame are applied. Chemical changes on the thermoplastic surfaces are verified by water contact angle measurement (CA) and X-ray photoelectron spectroscopy (XPS). Plasma treatment causes a decline in water contact angle, indicating the formation of functional groups, especially –OH, on the surface. XPS measurements confirm the increase of oxygen on the surface. Thus, the number of functional groups on the thermoplastic surface is enlarged by plasma treatment, leading to stronger bonding to the organofunctional silanes of the self-adhesive silicone rubber. A thin layer of silanol groups is created by the Pyrosil® flame on the thermoplastic substrates, which could be verified by XPS. A hydrophilic behaviour of the coated surface is noticed. Both surface modification methods lead to enhanced adhesion properties of self-adhesive LSR on thermoplastic surfaces. This is confirmed by 90°- peel tests of the injection-moulded composites leading to an increase in peel force by the applied surface modification techniques.

A new PvT device for high performance thermoplastics: Heat transfer analysis and crystallization kinetics identification

The quality of thermoplastic parts strongly depends on their thermal history during processing. Heat transfer modelling requires accurate knowledge of thermophysical properties and crystallization kinetics in conditions representative of the forming process. In this work, we present a new PvT apparatus and associated method to identify the crystallization kinetics under pressure. The PvT-xT mould was designed for high performance thermoplastics: high temperature (up to 400 °C), high cooling rate (up to 200 K/min) and very high pressure (up to 200 MPa). Specific volume measurements were performed at a low cooling rate to avoid a thermal gradient. The crystallization kinetics under pressure can be identified for a wide range of cooling rates by an inverse method taking into account the thermal and crystallinity gradients. Since identification is based on volume variations, the proposed methodology is non-intrusive. Furthermore, the enthalpy released by the crystallization was measured during the experiment by a heat flux sensor located in the moulding cavity.

Formulation and tensile characterization of wood–plastic composites

This study reports the effects of wood fibers and 3 wt% maleic anhydride-grafted polypropylene used as coupling agent on the tensile properties of polypropylene/wood composites. Compounding was done in a roller-based internal batch mixer followed by compression molding. Our findings show that both birch and aspen wood fibers improve the elastic modulus and the tensile strength of composites, and the chemical treatment improves the fiber–matrix interface. A comparison of experimental results’ elastic modulus with micromechanics theoretical models shows that the Lavengood–Goettler model is closer to experimental data. Also the results showed that the polypropylene/wood composites’ elastic modulus exceeds high-performance thermoplastics commonly used in gears manufacturing. Thus, the price of polypropylene/wood fibers makes it a viable alternative for similar application.

Incompatible blends of liquid crystalline polymers and engineering thermoplastic

The increasing demand of the high technology market for new applications in the aerospace industry has led to research on high performance thermoplastics as composite matrices. The inclusion of solid fibres in this class of materials during manufacturing may result in processing conditions that are too demanding. High temperature and pressure in stamping or injecting tools may result in thermal degradation of the organic matrix. Moreover, the load transfer through the fibre–matrix interface produces fibres breaking into fragments shorter than the critical length, affecting their aspect ratio, and consequently reducing the final performance of the product. The possibility of producing the reinforcing filler during the cooling cycle of the composite processing has suggested the definition of 'in situ' composite. In this paper the addition of thermotropic liquid crystalline polymer to engineering thermoplastics has been investigated. X–ray diffraction techniques have been used to evaluate the molecular orientation of the dispersed phase. The rheology and the mechanical properties of the in situ composites is related to the morphology of the material and to the processing operations.

Tailoring surface nanostructures on polyaryletherketones for load-bearing implants

High-performance thermoplastics including polyetheretherketone (PEEK) are key biomaterials for load-bearing implants. Plasma treatment of implants surfaces has been shown to chemically activate its surface, which is a prerequisite to achieve proper cell attachment. Oxygen plasma treatment of PEEK films results in very reproducible surface nanostructures and has been reported in the literature. Our goal is to apply the plasma treatment to another promising polymer, polyetherketoneketone (PEKK), and compare its characteristics to the ones of PEEK. Oxygen plasma treatments of plasma powers between 25 and 150 W were applied on 60 μm-thick PEKK and 100 μm-thick PEEK films. Analysis of the nanostructures by atomic force microscopy showed that the roughness increased and island density decreased with plasma power for both PEKK and PEEK films correlating with contact angle values without affecting bulk properties of the used films. Thermal analysis of the plasma-treated films shows that the plasma treatment does not change the bulk properties of the PEKK and PEEK films.

Mass Appeal

Plastics EngineeringVolume 69, Issue 7 p. 6-14 Cover Story Mass Appeal High-performance thermoplastics spark automakers' relentless drive to reduce weight and increase fuel economy Pat Toensmeier, Pat ToensmeierSearch for more papers by this author Pat Toensmeier, Pat ToensmeierSearch for more papers by this author First published: 01 July 2013 https://doi.org/10.1002/j.1941-9635.2013.tb01034.xCitations: 1AboutPDF ToolsExport citationAdd to favoritesTrack citation ShareShare Give accessShare full text accessShare full-text accessPlease review our Terms and Conditions of Use and check box below to share full-text version of article.I have read and accept the Wiley Online Library Terms and Conditions of UseShareable LinkUse the link below to share a full-text version of this article with your friends and colleagues. Learn more.Copy URL Share a linkShare onFacebookTwitterLinkedInRedditWechat Citing Literature Volume69, Issue7July-August 2013Pages 6-14 RelatedInformation

Influence of the Degree of Crystallinity on the Mechanical and Tribological Properties of High-Performance Thermoplastics Over a Wide Range of Temperatures: From Room Temperature up to 250°C

The mechanical characteristics of block-shaped samples of a number of thermally stable thermoplastics for structural applications are investigated over a wide range of temperatures: from the room temperature (RT) up to 250°C. Together with several commercially available materials, namely, polyetheretherketone, polyphenylene sulfide, and a polyetherimide Ultem-1000; a number of polyimide thermoplastics designed at the Institute of Macromolecular Compounds RAS having both semicrystalline and amorphous structures were studied. The tribological behavior of these thermoplastics was investigated in the tribometers of different types using polymer–steel couples with the variation of both the temperature (from RT to 250°C) and the contact pressure. The experimental determination of the overheating values of the contact surface of the polymer sample was carried out during the friction process at different medium temperatures. The possibilities of obtaining a maximally broad temperature range for applications of thermoplastic polymeric material by regulating the degree of its structural ordering are analyzed.

Random copolymer of styrene and diene derivatives via anionic living polymerization followed by intramolecular Friedel–Crafts cyclization for high-performance thermoplastics

Rubbery random copolymers of styrenes and dienes prepared via anionic living polymerizations were intramolecularly cyclized into high-performance thermoplastics.

Experimental analysis of drilling damage in carbon-fiber reinforced thermoplastic laminates manufactured by resin transfer molding

The emergence of new high-performance thermoplastics to replace thermosets in fiber-reinforced polymers puts up a new challenge: their machining. In this study, carbon fiber-reinforced poly-cyclic butylene terephthalate laminates were manufactured, drilled, and inspected. Different commercial drill geometries and machining conditions were compared. Roughness, microscopy, and non-destructive tests allowed us to determine the hole quality as well as delamination. The surface tests showed better results after working at the most common cutting speed (3000 rpm) than at high speed (15,000 rpm) with a constant feed rate. This fact can be explained based on the viscoelastic properties of the matrix that becomes fragile at high cutting speeds. The Delamination factor obtained by means of Ultrasonics and X-ray Computed Tomography also confirmed that the best results are achieved with a Twist drill bit at 3000 rpm. In contrast to carbon fiber-reinforced thermosets, the detected delamination at high cutting speeds is not as remarkable as expected. These results allow us to conclude that this new composite will certainly increase production rate without delamination damage. Chip formation takes also a special role. It can be recovered to be used as reinforcement in manufacturing processes due to the recyclability of the thermoplastic matrix.

Enhanced Continuous Glass Fibre-Reinforced Poly(phthalazinone ether sulfone ketone) Composites by Blending Polyetherimide and Polyethersulfone

Poly(phthalazinone ether sulfone ketone) (PPESK) is a novel high performance thermoplastic with outstanding high temperature resistance and excellent mechanical properties and therefore, it is a very ideal candidate matrix for advanced composites. However, the high melt viscosity of PPESK makes it difficult to melt-process. In this paper, two well-known high performance thermoplastics, polyetherimide (PEI) and polyethersulfone (PES) were introduced into PPESK in order to reduce its melt viscosity and to improve the properties of its composites. The effect of the addition of PEI and PES on the resultant composites was studied. A series of unidirectional composites was made from PPESK and its PEI and PES blends as matrices and continuous glass fibre as reinforcement. The solution prepregging method and hot-press moulding method were used in the preparation of composites. The effects of the polymer blend matrices on the mechanical properties, interfacial adhesion and fracture mode were studied by three point bending, interlaminar shearing, porosity measurements and SEM microscopy. The results showed that the mechanical properties and interfacial adhesion increased and the porosity decreased after blending PEI or PES in the matrix. Addition of PEI and PES to PPESK also resulted in an obvious transition of fracture mode.

New hybrid nanocomposites containing carbon nanotubes, inorganic fullerene-like WS2 nanoparticles and poly(ether ether ketone) (PEEK)

Single-walled carbon nanotubes (SWCNTs) and inorganic fullerene-like WS2 nanoparticles were successfully dispersed in poly(ether ether ketone) (PEEK) by advantageously traditional melt processing techniques. This strategy offers an attractive way to combine the merits of organic and inorganic materials into novel hybrid systems that challenge emerging polymer/CNT nanocomposites in terms of performance, cost and processability. In particular, the incorporation of IF-WS2 has shown to be efficient to produce well-dispersed PEEK/SWCNT composites influenced in turn by the processing method. The morphology, thermal stability, crystallization behaviour, thermal conductivity as well as mechanical and electrical properties of PEEK/SWCNT composites were tuneable by the introduction of small amounts of IF-WS2. The overall structural, thermal, mechanical and electrical performances confirm the potential use of SWCNTs and IF-WS2 for the preparation of advanced hybrid nanocomposites as lightweight alternatives for use in critical industrial applications of high-performance and high-temperature thermoplastics like PEEK.

Microstructure and mechanical properties of flame-sprayed PEEK coating remelted by laser process

Poly-ether-ether-ketone (PEEK) is one of the high-performance thermoplastics. It is being increasingly used for many industrial applications due to its excellent properties. In this paper, a flame spraying technique is used to deposit PEEK coating on 304L stainless substrates. CO 2 and Nd:YAG laser treatments are chosen to remelt the as-sprayed polymer coating to get a dense coating. The microstructures of the as-sprayed and remelted coatings are characterized by SEM and XRD. The results show that both CO 2 and Nd:YAG lasers are suitable for densifying the PEEK coating on stainless substrate. However, the remelted coatings present different crystalline structure due to their laser processing parameters. Hardness measurements, tribological and scratch tests are conducted to characterize the mechanical properties of remelted coating. The coatings’ mechanical properties are correlated with their structures.

Modified continuous carbon fiber‐reinforced poly(phthalazinone ether sulfone ketone) composites by blending polyetherimide and polyethersulfone

AbstractPoly(phthalazinone ether sulfone ketone) (PPESK) is a novel high performance thermoplastic with outstanding high temperature resistance and excellent mechanical properties and therefore, it is a very ideal candidate matrix for advanced composites. However, its high melting viscosity makes the melting process difficult. In this article, two well‐known high performance thermoplastics, polyetherimide (PEI) and polyethersulfone (PES) were introduced to PPESK in order to reduce the melting viscosity of PPESK and to improve the properties of composites. The effect of addition of PEI and PES on the resultant composites was studied. A series of unidirectional composites were made of PPESK and its PEI and PES blends as matrix and continuous carbon fiber (T700) as reinforcement. The solution prepregging method and hot‐press molding method were used in preparation of composites. The effects of polymer blends matrix on mechanical properties, interfacial adhesion, and fracture mode were studied by three points bending, interlaminar shearing, porosity, and scanning electron microscope test. The results show that the mechanical properties and interfacial adhesion increases, and the porosity decrease after blending PEI or PES in the matrix. Addition of PEI and PES to PPESK results in an obvious transition of fracture mode. POLYM. COMPOS., 2009. © 2008 Society of Plastics Engineers

High-Performance Thermoplastics

Plastics EngineeringVolume 63, Issue 6 p. 18-22 Europe High-Performance Thermoplastics Peter Mapleston, Peter MaplestonSearch for more papers by this author Peter Mapleston, Peter MaplestonSearch for more papers by this author First published: 01 June 2007 https://doi.org/10.1002/j.1941-9635.2007.tb00131.xAboutPDF ToolsExport citationAdd to favoritesTrack citation ShareShare Give accessShare full text accessShare full-text accessPlease review our Terms and Conditions of Use and check box below to share full-text version of article.I have read and accept the Wiley Online Library Terms and Conditions of UseShareable LinkUse the link below to share a full-text version of this article with your friends and colleagues. Learn more.Copy URL Share a linkShare onFacebookTwitterLinkedInRedditWechat Volume63, Issue6June 2007Pages 18-22 RelatedInformation