Polyphenylene Sulfide Matrix Research Articles

Study on the epoxy bonding properties of polyphenylene sulfide matrix composites reinforced by montmorillonite and basalt fiber

To improve the epoxy bonding properties of polyphenylene sulfide (PPS) matrix composites, CK-MMT and K-BF were prepared by modifying montmorillonite (MMT) and basalt fiber (BF) with cetyl trimethyl ammonium bromide (CTAB) and 3-Glycidyloxypropyltrimethoxysilane (KH-560) as the modifiers. CK-MMT/BF/TPU/PPS composites were prepared by injection moulding. The surface properties of the composites were tested and characterized by scanning electron microscopy (SEM) and X-ray photoelectron spectroscopy (XPS), etc. The epoxy bonding and mechanical properties were studied by combining the single-lap-joint tensile shear strength test and notched impact test. The results demonstrated the successful preparation of the modified MMT and BF. With the addition of CK-MMT and K-BF in different ratios, the surface roughness and the contents of polar groups of the composites increased, which could effectively improve the epoxy bonding properties of PPS matrix composites. When the additions of CK-MMT and K-BF were 10 and 25 wt%, respectively, the composites had the best overall properties. It demonstrated a single-lap-joint tensile shear strength was 7.56 MPa, representing a 220.34% increase over that of thermoplastic polyurethane/polyphenylene sulfide (TPU/PPS) and a 477.10% increase over that of pure PPS.

Tensile behavior of angle ply carbon reinforced PPS laminates under severe thermal aggressions: Homogeneous and heterogeneous temperature conditions

AbstractThis study explores the effects of critical temperature conditions on carbon fiber‐reinforced Poly Phenylene Sulfide (PPS) laminates, focusing on the coupling between thermal and mechanical behaviors. The thermo‐mechanical behavior of angle‐ply laminates is examined under both homogeneous (thermal decomposition and deformation/damage) and heterogeneous (fire) conditions following three primary objectives: (i) Investigate the impact of temperature distribution on the formation of porosities within the composite, considering their significance in thermal transfer and stress concentration—(ii) Evaluate the changes in residual mechanical behavior and properties under tension due to thermally‐induced damage—(iii) Improve the understanding of the interactions between severe thermal exposures and the mechanical behavior. X‐ray tomographic analyses and tensile tests were conducted to achieve these goals. Porosities resulting from thermal damage are identified as a key factor affecting the structural integrity of C/PPS laminates for high‐temperature applications. Mechanical testing reveals that the porosity content significantly reduces the tensile properties (axial stiffness and strength). Under homogeneous temperature conditions, the decrease in the tensile properties is significant up to Tonset (465°C) from which both the axial strength and stiffness dramatically decrease by −75 and −50%, respectively. As exposed to a kerosene flame during 60 s, corresponding to an aggression of 115 kW/m2 on one face of the laminates, the retention of the residual tensile properties remains good (−12% and −22% in stiffness and strength respectively), despite the dramatic decomposition of the polymer matrix. This can be explained from the stress redistribution from the exposed to the back face, and from the role of thermal insulator played by porosities.Highlights Carbon fibers/PPS laminates were subjected to severe thermal aggressions The formation of thermally‐induced porosities is studied A homogeneous aggression significantly decrease the tensile properties (−75%) Once the PPS matrix is severely decomposed, the load transfer is not possible After a 60 s flame exposure, the retention of tensile properties is good (−20%)

Improving the interfacial adhesion between recycled carbon fibres and polyphenylene sulphide by bio-inspired dopamine for advanced composites manufacturing

Polyphenylene sulphide composites with recycled carbon fibres are of high interest due to their promising mechanical properties. Poor interface adhesion between recycled carbon fibre and thermoplastic matrix, however, remains a major problem in composite manufacturing. Herein, a novel one-step method using bio-inspired copolymerisation of dopamine to graft silica nanoparticles onto the carbon fibre surface is reported. Comprehensive investigations were conducted to fabricate the treated carbon fibre and characterise the modified samples by analysing the surface morphology and functional groups. The experimental results reveal that the network of bio-inspired adhesive polydopamine and nanoparticles adhering to the fibres can improve inter-laminar shear strength by 28.4% in the resulting composites. In addition, dynamical mechanical analysis results prove that the interfacial bonding at the fibre/matrix interface provides good resistance to thermal cycling. This novel approach introduces the functional groups on the recycled carbon fibre surface, leading to an improvement of surface energy and wettability between the carbon fibres and polyphenylene sulphide matrix and constitutes a robust and green approach to the manufacturing of advanced composites.

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.

Characterization of PPS Piston and Packing Ring Materials for High-Pressure Hydrogen Applications.

The widespread adoption of renewable energy hinges on the efficient transportation of hydrogen. Reciprocating piston compressor technology in non-lubricated operation will play a key role, ensuring high flow rates and compression ratios. These systems rely on advanced high-strength sealing solutions for piston and rod packing rings utilizing advanced fiber-reinforced polymers. Polyphenylene sulfide (PPS) polymer matrix composites have seen use in tribological applications and promise high mechanical strength and wear resistance. The presented work describes carbon and glass fiber-reinforced PPS matrix polymers in comparison, which are characterized by complementary methods to investigate their properties and potential for application in reciprocating compressor under non-lubricated operation. Thermo-mechanical and tribological testing was supported by microstructure analysis utilizing advanced X-ray and electron imaging techniques. New insights in micromechanical deformation behavior in regard to fiber materials, interface strength and orientation in fiber-reinforced polymers are given. Conclusions on the suitability of different PPS matrix composites for high-pressure hydrogen compression applications were obtained.

Development of high-flowability melt PPS-based composites through blending with g-C3N4

Polyphenylene sulfide (PPS), commonly used as a core material for high-temperature flue gas treatment, exhibits elevated viscosity when processed even at temperature exceeding 280 °C. In this study, a novel high-flowability PPS-based composite was fabricated through the incorporation of graphitic carbon nitride (g-C3N4) via a well-established melt extrusion procedure. The enhancement of flowability in PPS was verified, and the material's texture structures and fundamental properties of composites with varying contents were determined. The composites exhibit well-dispersed g-C3N4, a significant reduction in shear viscosity (>10 %), a notable increase in melt index (>30 %), improved crystallinity, and comparable or superior performance compared to pure PPS. When the g-C3N4 was introduced into the PPS matrix, a phase-separated composite structure was formed. This structure reduces the entanglement degree between the PPS molecular chains and provides more space for free-movement of the PPS chains, and thus the improvement in flowability for the composites can be clearly demonstrated. Therefore, g-C3N4 can be used as a novel flow modifier to enhance the flowability and stability of PPS resin without compromising its fundamental properties, which offers significant prospects for improving productivity, optimizing energy usage, and managing costs for PPS-based products.

Thermal degradation and performance evolution mechanism of fully recyclable 3D printed continuous fiber self-reinforced composites

An innovative recycling method that does not require separation of the reinforcement and matrix is been proposed based on 3D printing of continuous fiber self-reinforced composites. The continuous fiber self-reinforced polyphenylene sulfide (PPS) composites were mechanically ground and directly remanufactured by screw extrusion 3D printing. The recycling procedure was accelerated and the thermal processing of the material was reduced. This recycling paradigm of self-reinforced composites with in-situ resource utilization is ideally suited to the space environment. The recycled self-reinforced composites showed no significant loss in tensile properties and even exhibited a slight increase after multiple recycling cycles owing to the melted PPS fiber in comparison with original PPS matrix. Since recycled material didn't separate the fiber from the matrix, its flexural strength and modulus increased by 34.11% and 51.81%, respectively, when compared to original PPS matrix. Molecular structure, rheological changes, and crystallization behavior were systematically investigated to elaborate the thermal degradation mechanism of recycled composites. The results obtained from systematical characterizations indicated that the recycled composites formed the cross-linking structure when subjected to multiple screw extrusion processing. The energy consumption of the screw extrusion-based 3D printing method was also conducted. The total energy intensity of recycling and remanufacturing processes were only about 17.9 MJ/kg. Spatial suitability, considering the advantages of self-reinforced composite recycling for space applications, were analyzed. Finally, theoretical material recovery rate of 100% for self-reinforced composites opens the prospect to reduce maintenance logistics in space. A future application scenario for fully recyclable self-reinforced composites in space was explored.

Skinless Polyphenylene Sulfide Foam with Enhanced Thermal Insulation Properties Fabricated by Constructing Aligned Gas Barrier Layers for Surface-Constrained sc-CO2 Foaming.

A solid skin layer inevitably forms on the foam surface for supercritical carbon dioxide (sc-CO2) foaming technology, leading to deterioration of some inherent properties of polymeric foams. In this work, skinless polyphenylene sulfide (PPS) foam was fabricated with a surface-constrained sc-CO2 foaming method by innovatively constructing aligned epoxy resin/ferromagnetic graphene oxide composites (EP/GO@Fe3O4) as a CO2 barrier layer under a magnetic field. Introduction of GO@Fe3O4 and its ordered alignment led to an obvious decrease in the CO2 permeability coefficient of the barrier layer, a significant increase of the CO2 concentration in the PPS matrix, and a decrease of desorption diffusivity in the depressurization stage, suggesting that the composite layers effectively inhibited the escape of CO2 dissolved in the matrix. Meanwhile, the strong interfacial interaction between the composite layer and the PPS matrix remarkably enhanced the heterogeneous nucleation of cells at the interface, resulting in elimination of the solid skin layer and formation of an obvious cellular structure on the foam surface. Moreover, by the alignment of GO@Fe3O4 in EP, the CO2 permeability coefficient of the barrier layer became much lower, and the cell density on the foam surface further increased with decreasing cell size, which was even higher than that of the cross section of foam, attributed to stronger heterogeneous nucleation at the interface than the homogeneous nucleation in the core region of the sample. As a result, the thermal conductivity of the skinless PPS foam reached as low as 0.0365 W/m·k, decreasing by 49.5% compared with that of regular PPS foam, showing a remarkable improvement in the thermal insulation properties of PPS foam. This work provided a novel and effective method for fabricating skinless PPS foam with enhanced thermal insulation properties.

Effect of quercetin on the structure and oxidation resistance of polyphenylene sulfide fiber prepared by melt spinning

Polyphenylene sulfide fiber is easily oxidized at high temperature, thus vastly reducing its application range. In this study, polyphenylene sulfide/quercetin fibers were prepared via melt spinning. The effect of quercetin on the spinnability of the composite fibers was explored, and their cross-sectional morphology, crystalline properties, orientation, tensile properties, thermal stability and oxidation stability were investigated. At the quercetin content of 1.5 wt.%, particle agglomerates and some gasification, causing fluctuations in melt pressure, fiber breakage and poor spinnability, were observed in the polyphenylene sulfide matrix. The addition of quercetin can increase the crystallization temperature of polyphenylene sulfide, shorten its crystallization time, refine the crystalline particles therein, and improve the degree of fiber orientation. At the quercetin content of 1.0 wt.%, the tensile strength and elongation at break of composite fibers increased by 30.8% and 7.6%, respectively, as compared to those of pure polyphenylene sulfide fibers. Moreover, the decomposition temperature and the oxidation induction temperature at a 5% weight loss were 16.3°C and 13.4°C higher than those of the unmodified PPS fibers. The loss of strength of composite fibers subjected to oxidation for 240 h was only 18.4%. The X-ray diffraction results showed that the phenolic hydroxyl groups in the quercetin structure were able to capture free radicals generated during the oxidation of polyphenylene sulfide fibers, as well as inhibit the oxidative degradation reaction and improve the oxidative stability of the fiber. The oxidation resistance mechanism of composite fibers was also proposed.

Tribological properties of cyclic phenylene sulfide heat‐treated carbon fiber/polyphenylene sulfide composites

AbstractHigh‐performance self‐lubricating polyphenylene sulfide (PPS)/carbon fiber (CF) composites were obtained by treating the CF surface with heat‐treated cyclic phenylene sulfide oligomers (CPS). The influence of CPS treat conditions on the structure and properties such as mechanical and tribological performance of the composites were studied in detail. The results indicate that the PPS/CPS‐sized CF composites exhibit higher mechanical strength and better tribological performance than the PPS/original CF composites, especially under the condition of higher loads and speeds (300 N × 200 rpm and 200 N × 200 rpm). The performance enhancement is reasonably ascribed to the improved compatibility of the modified CF with the PPS matrix. Further structural analysis reveals that the modified CF treated at 300°C under N2(CF‐300N) has the most similar structure to the PPS matrix, which makes the comprehensive performances of PPS/CF‐300N composites superior to the products obtained under the other heat‐treatment conditions.

Polyphenylene sulfide-modified carbon fiber reinforced high-strength composites via electrophoretic deposition

The performance of carbon fiber (CF)–reinforced thermoplastic composites is influenced by the interfacial adhesion strength of the fiber and thermoplastic matrix. In this study, the electrophoretic coating of silane-grafted polyphenylene sulfide (PPS) particles on the CF surface was used to quantitatively control the interfacial adhesion between the CF and PPS matrix. The mechanism of the modification method was discussed, and the interfacial shear strength of the CF/PPS composites was numerically and experimentally investigated and found to be significantly higher (65.8 ± 4.76 MPa) than that of conventional thermoplastic systems. Scanning electron and atomic force microscopies of the fractured surfaces confirmed that the predominant failure mechanisms involved the deformation and breakage of the matrix due to the strong interphase in the interfacial region. A straightforward and controllable electrophoretic coating process was shown to be effective at improving the interfacial strength and mechanical properties of CF/PPS composites.

Thermal Aging Effects on the Mechanical Behavior of Glass-Fiber-Reinforced Polyphenylene Sulfide Composites.

In this article, the thermal aging behavior of polyphenylene sulfide (PPS) composites, reinforced by 20% glass fibers (GFs), in thermal aging temperatures ranging from 85 to 145 °C was studied. Tensile and bending properties and color changes in the thermally aged samples were investigated. The results showed that thermal aging at this temperature range resulted in the degradation of mechanical properties. Both the tensile and flexural strength of the GF/PPS composites were significantly reduced after thermal aging at 145 °C. Decreased strength and brittle fracture were observed because thermal aging at high temperatures resulted in the deterioration of the interfaces between the GFs and PPS matrix. The degradation of the mechanical properties of the composite samples can be reflected by the color change, which means that the mechanical properties of the GF/PPS composite samples under thermal aging are predictable using color change analysis.

Role of E-glass fiber on mechanical, thermal and electrical properties of polyphenylene sulfide (PPS) composites

The present work focusses on the fabrication and characterization of E-glass fiber reinforced Polyphenylene Sulfide (PPS) composites. The composites were fabricated using compression molding method. The fabricated composites were characterized for mechanical properties such as tensile, flexural, impact properties and thermal properties like heat distortion of neat PPS and glass fiber reinforced composites. The various percentages such as 10, 20, 30 and 40 wt% of glass fiber was added into the PPS matrix to analyse the role of the same on mechanical, thermal and electrical properties. The results exposed that, the PPS composites filled with 30 wt% of glass fiber was found to be optimum in terms of mechanical properties such as tensile, flexural, impact strength and dielectric strength compared to neat PPS and other weight percentages. The Heat Distortion Temperature (HDT) was considerably higher than the neat PPS as a result of the high strength and high glass transition temperature of the glass.

Automatically controlled laser-based welding process for repair of CFRP parts

Due to a high strength-to-weight ratio, carbon fiber-reinforced plastics (CFRPs) have become a standard in the lightweight industry, which results in the development of new machining and repairing methods. Specifically, CFRP with a thermoplastic matrix material is more attractive for many applications as a thermosetting matrix material. Thermoplastic matrix materials enable new joining processes due to their thermoformability and weldability. Currently, the repair process is mainly executed manually. In order to reduce repair costs, an automated, reliable, and fast process is needed. For the new laser-based repair process, first a scarf joint is prepared in a CFRP laminate consisting of a thermoplastic polyphenylene sulfide matrix material. To refill the scarf, a patch with the same matrix material and fiber setup as the original laminate is cut into shape and welded into the scarf area. In order to obtain a reliable and stable welding process resulting in high weld seam qualities, an automated controlled welding process is being used, which controls the laser power via the surface temperature, which is detected by a pyrometer. For the development of the welding process, the influence of the welding time and the surface temperature on the resulting weld seam quality were evaluated. For the analysis of the joining quality, overlap samples were welded and tested in order to determine the weld seam strength. In addition, cross sections were prepared and analyzed with a microscope. Finally, the measured results were correlated in order to determine a parameter set generating a high-quality weld seam.

Investigation of mechanical and tribological behaviour of expanded perlite particle reinforced polyphenylene sulphide

In this study, polyphenylene sulphide was used as a matrix material due to its superior engineering properties. Expanded perlite is formed substantially from silica oxides, and it is a volcanic based and porous structure material. Its low price and low density make it very usable as a filler material. For this reason, expanded perlite reinforced polyphenylene sulphide matrix composites were prepared at various weight ratios (0, 1, 3, 5, and 10 wt%). Mechanical and tribological characterizations were done with tensile tests, hardness measurements, solid particle erosion, ball on disc, and scratch tests. According to the tensile test results, a synergistic effect was observed in mechanical properties by using perlite as a reinforcing agent. As expected, perlite reinforcement resulted in an increase in the modulus of 54% in composites. As well as tensile strength of the composite increased by approximately 13%. Furthermore, the perlite particle reinforcement improved the adhesion resistance by 73% and the scratch resistance by 30%. On the other hand, especially at low impact angles, perlite particle reinforcement decreased the erosive wear resistance of the pure polyphenylene sulphide polymer by 50%. Furthermore, expanded perlite reinforcement decreased the plastic deformation ability of polyphenylene sulphide. In consequence of this study, it has been found that expanded perlite particles can be used as an alternative filler instead of conventional reinforcing particles.

Structural, Thermal, and Mechanical Characterization of a Thermally Conductive Polymer Composite for Heat Exchanger Applications.

Polymer composites are being considered for numerous thermal applications because of their inherent benefits, such as light weight, corrosion resistance, and reduced cost. In this work, the microstructural, thermal, and mechanical properties of a 3D printed polymer composite with high thermal conductivity are examined using multiple characterization techniques. Infrared spectroscopy and X-ray diffraction reveal that the composite contains a polyphenylene sulfide matrix with graphitic fillers, which is responsible for the high thermal conductivity. Furthermore, differential scanning calorimetry determines that the glass transition and melting point of the composite are 87.6 °C and 285.6 °C, respectively. Thermogravimetric analysis reveals that the composite is thermally stable up to ~400 °C. Creep tests are performed at different isotherms to evaluate the long-term performance of the composite. The creep result indicates that the composite can maintain mechanical integrity when used below its glass transition temperature. Nanoindentation tests reveal that modulus and hardness of the composite is not significantly influenced by heating or creep conditions. These findings indicate that the composite is potentially suitable for heat exchanger applications.

Thermo-mechanical characterization of discontinuous recycled/repurposed carbon fiber reinforced thermoplastic organosheet composites

The integration of repurposed and recycled carbon fibers into high-performance composites is essential to the adoption of composites for automotive structures due to their low-cost, high formability, and reduced environmental impact. When high areal density nonwovens of these fibers are infused with a semi-crystalline thermoplastic resin, organosheets offering competitive mechanical properties can be produced. This study examined the optimization of such composites through multiscale material characterization and post-process annealing. Single fiber tensile tests were used to characterize repurposed and recycled fiber formats. The thermomechanical properties of the polyphenylene sulfide matrix and resulting composites subjected to different post-process annealing conditions were characterized using differential scanning calorimetry, dynamic mechanical analysis, and nano-indentation. Single fiber push-in testing was conducted to evaluate the fiber–matrix interface as a function of annealing. It was shown that statistical methods based on the bootstrap principle successfully identify the effects of post-process annealing, which are otherwise masked by material inhomogeneity. Post-process annealing was shown to be an effective method of improving the resulting mechanical properties of repurposed and recycled carbon fiber organosheet composites, thereby optimizing their properties for use as a high-performance automotive structural material.

Effect of montmorillonite on the oxidative stability of polyphenylene sulfide fibers prepared by melt spinning

Masterbatches of polyphenylene sulfide (PPS)/organic montmorillonite (MMT) composites were produced via melt blending. A self-made spinning equipment was then used to produce the PPS/organic MMT composite fibers by melt spinning directly from the masterbatches. X-ray diffractometer and transmission electron microscope were used to examine the dispersibility of organic MMT. The morphology, tensile property, crystallization behavior, and oxidative stability of PPS fibers were investigated. The results indicated that organic MMT could be uniformly distributed in the PPS matrix to form a mixed dispersion of intercalated and exfoliated structure and influence the longitudinal surface morphology of fibers to become rough. The roughness of composite fibers surface was proportional to the content of organic MMT. The organic MMT nanolayers could act as the heterogeneous nucleating agents to improve the crystallization, and the crystallity of composite fibers increased with the increase of organic MMT content. The breaking strength of composite fibers first increased and then decreased by increasing the amount of organic MMT. After the oxidation treatment, the breaking strength of neat PPS fibers and composite fibers declined, but the degree of breaking strength loss for composite fibers is lower than that of neat PPS fibers. The dynamic oxidation induction temperature of composite fibers also showed a significant increase by adding organic MMT. Moreover, the addition of organic MMT could limit the chemical combination of element sulfur and oxygen, retard the generation of sulfoxide groups, and induce the conversion of sulfur atoms from C-S bond to sulfone for improving oxidative stability.

The Performance Promotion of Polyphenylene Sulfide Fibers Based on the Hygroscopic and Dyeable Characteristics

The hygroscopic and dyeable polyphenylene sulfide (PPS) composite fiber was prepared using a twin-screw extruder and a melt spinning machine. A new dyeing process was proposed and the moisture absorption and dyeing mechanism of the composite fiber was analyzed. The results show that sodium polyacrylate (PAAS) is uniformly dispersed in the PPS matrix and is compatible with PPS at the macromolecular level. The thermal properties of the composite fibers are basically unchanged, and the crystallinity is slightly reduced. With the increase of PAAS content, the normal moisture regain of the composite fiber reached 2.11 % from 0.21 %, and the contact angle decreased from 73.8 ° to 52.3 °. Under the new dyeing technology, the dyeing rate of the composite fiber reached 93 %, and the washing fastness was grade 5. The mechanism of hygroscopicity and dyeing of macromolecular space networks and polyelectrolyte was proposed.

Preparation and oxidation resistance of polyphenylene sulfide modified by high-temperature antioxidants

Two types of high-temperature antioxidants (Revonox 608 and GA-80) were used to improve the oxidation resistance of polyphenylene sulfide (PPS) through melt blending, and the resistance against oxidation and other properties were characterized. The results showed that GA-80 exhibited better dispersibility and compatibility with the PPS matrix than did Revonox 608. Revonox 608 could act as a heterogeneous nucleation agent that can promote crystallization and improve the crystallinity of PPS, whereas GA-80 could delay the movement of chain segments and limit crystallization. The thermal-oxidative stability of PPS can be improved by adding antioxidants due to prior oxidative decomposition. The dynamic oxidation induction temperature of PPS increased by more than 10 °C because of the capture of free radicals and the decomposition of hydroperoxides by antioxidants. The XPS results showed that both GA-80 and Revonox 608 could retard the oxidative cleavage of the C-S-C bond in the PPS macromolecular chains and protect the S atoms from oxidizing to sulfone groups.