Powder Impregnation Process Research Articles

Optimization of Powder Impregnation Process Parameters of Carbon Fiber Reinforced Polyether-ether-ketone Prepreg Tape by Response Surface Methodology

Optimization of Powder Impregnation Process Parameters of Carbon Fiber Reinforced Polyether-ether-ketone Prepreg Tape by Response Surface Methodology

Effect of carbon nanotubes on the electrical, thermal, mechanical properties and crystallization behavior of continuous carbon fiber reinforced polyether-ether-ketone composites

The continuous carbon fiber reinforced Polyether-ether-ketone (PEEK) prepreg tapes with the addition of carbon nanotubes (CNTs) were prepared by a wet powder impregnation process. Their electrical conductivity, thermal conductivity, the tensile properties, dynamic mechanical behavior, fracture morphology and crystallization melting behavior were investigated. The results show that, the electrical conductivity (σ), thermal conductivity (λ), tensile strength (σ t) and interfacial adhesion of the prepreg tapes were obviously improved with the addition of CNTs. When CNT content was 1.0 wt%, the σ of CNT/CCF/PEEK prepreg tapes in the 0° direction reached a maximum value of 0.701 s cm−1, which was increased 165% than that of CCF/PEEK prepreg tapes. The λ reached 1.053 W m−1·K−1, which was improved by 12.14%. The tensile strength was 1489 MPa, which was increased by 16.4%. The results of SEM images show that the interface adhesion between the fiber and the matrix is good. The results of DMA indicate that, the capability of deformation resistance of the prepreg tapes were further improved with the addition of CNTs. When the temperature was 280 °C, the decline rate of E′ of 1.0 wt% CNT/CCF/PEEK prepreg tapes were 3.58%. The results of DSC indicate that, the T c of CNT/CCF/PEEK prepreg tapes moved to high temperature after adding CNTs, which indicate that CNTs played a role of heterogeneous nucleation in the PEEK matrix.

Crystallization and Mechanical Properties of Continuous Carbon Fiber Reinforced Polyether-ether-ketone Composites

The effect of two different continuous carbon fibers (CCF1 and CCF2) with different material properties on structure-properties of continuous carbon fibers reinforced polyether-ether-ketone prepreg tapes (CCF/PEEKPT) prepared by a wet powder impregnation process were investigated. The effects of fiber content on the tensile properties, dynamic mechanical behavior, crystallization melting behavior and fracture morphology of prepared prepreg tapes were performed by the dynamic mechanical analysis (DMA), differential scanning calorimetry (DSC) and scanning electron microscope (SEM) etc. The results showed that, the tensile strength of CCF1/PEEKPT increased with increasing of the carbon fiber content within 50–75 wt%. Meanwhile, the tensile strength of 50–65 wt% CCF2/PEEKPT had the same change trend, but then decreased when the fiber content of composites was higher than 65 wt%. The storage modulus (E′) of composites increased with adding content of carbon fiber. The composites still maintained high deformation resistance when the temperature rose to 290 °C. Compared with pure PEEK, the crystallinity and crystallization rate of the composites both increased with the occurrence of fiber inducing PEEK crystallization, but the crystallization onset temperature, crystallization temperature and melting temperature of CCF/PEEKPT moved to low temperatures with adding of fiber content. In general, these observations suggested that CCF hindered the movement of the polymer chain segment and constrained the spherulites growth of PEEK for CCF/PEEKPT.

The mechanical properties of plasma‐treated carbon fiber reinforced PA6 composites with CNT

The aim of this work is the evaluation of the effects of plasma treatment and the addition of CNT on the mechanical properties of carbon fibre/PA6 composite. A powder impregnation process with integrated inline continuous plasma of carbon fibers was used to produce CF/PA6 composite. CF/PA6 composite was processed into test laminates by compression moulding, and interface dominated composite properties were studied. The tensile and impact strength of composites containing CNT and plasma‐treated carbon fibres improved obviously. The tensile strength of nanocomposite largely increases with the increasing of the CNT content and then decreases when the CNT content is over 2%. The hydroxyl groups of the fibers surface are in favor of the wettability of carbon fibers by the polar matrix resin, which is resulting in a further interaction of the fiber surface with the curing system of the matrix resin.

Mechanical properties of unidirectional continuous fiber tapes reinforced long fiber thermoplastics and their manufacturing

In this paper, long fiber thermoplastic was prepared by in-line compounding process and premixed powder impregnation process, respectively, and then comolded with unidirectional continuous fiber tapes. The endless fiber reinforced long fiber thermoplastic was obtained. The effect of the endless fiber fraction on the properties was studied through varying the thickness of the unidirectional composite. It is discovered that the unidirectional continuous fiber can improve toughness dramatically, without sacrificing the strength and stiffness. Fiber length and fiber length distribution may be the significant factors that influence the mechanical properties, especially toughness which can be toughened by fiber bundles as well. The rule of hybrid mixture is suitable to estimate the impact strength.

Combining product engineering and inherent safety to improve the powder impregnation process

The functionalization of nonwoven textiles can be realized by dry powder impregnation. In order to develop and improve this process, two complementary approaches have been combined: product engineering and inherent safety. It consists in integrating ab-initio consumers' requirements, production constraints as well as safety and environmental considerations. This case study is focused on the proposal, the characterization and the selection of powders mixtures of flame retardants and copolyesters, which will be used to create fire-proofed textiles. The influences of the chemical natures of the flame retardant (e.g. calcium carbonate, aluminium trihydroxide, ammonium polyphosphates), their respective concentrations, particle diameters and the addition of silica to flame retardant/polymer mixtures on their minimum ignition energy has been investigated. It has been determined that ammonium polyphosphates are far more efficient than other flame-retardants and that a minimum of 20%wt. concentration is needed to generate a powder mixture that will be almost insensitive to ignition by an electrostatic source. Modifying the particle size distribution and introducing glidants play also a significant role on flame retardant/polymer interactions, on powder dispersibility and has a strong impact on the minimum ignition energy. Finally, the formulations which have been selected fulfill the requirements for fire resistance, flowability, prevention of dust explosion; they are non-toxic, environmentally friendly and their cost is reduced.

The preparation and mechanical properties of novel PVA/SiO2 film

The aim of this work is the evaluation of the mechanical properties of composite PVA/SiO2. A powder impregnation process with integrated inline continuous plasma of SiO2 was used to produce PVA/SiO2 composite. PVA/SiO2 composite was processed into test laminates by compression mounding and the interface-dominated composite properties were studied. When compared to PVA, the mechanical properties of PVA/SiO2 were significantly increased, such as tensile strength, tensile modulus and elongation at break, and the damping capacity of PVA/SiO2 film increased with increasing ratio of SiO2.

The mechanical properties of oxygen plasma-treated carbon nanotube and silicon dioxide-reinforced polytetrafluoroethylene composite film

The aim of this work is to evaluate the effects of oxidation treatment and the addition of silicon dioxide (SiO2) on the mechanical properties of carbon nanotube (CNT)/polytetrafluoroethylene (PTFE) composite film. A powder impregnation process with integrated inline continuous oxidation of CNTs was used to produce CNT/PTFE composite. CNT/PTFE composite was processed into test laminates by compression molding, and interface-dominated composite properties were studied. The tensile strength of composites-containing SiO2 and oxidation-treated CNT improved obviously.

Mechanical Property Improvement of Plasma Treated Carbon Fiber-Reinforced Polyurethanes (PUR) Composites with SiO2 Filler

The aim of this work is the evaluation of the effects of plasma treatment and the addition of SiO2 on the mechanical properties of carbon fiber/polyurethanes (PUR) composite. A powder impregnation process with integrated inline continuous plasma of carbon fibers was used to produce CF/PUR composite. CF/PUR composite were processed into test laminates by compression moulding and interface dominated composite properties were studied. The tensile, flexural and impact strength of composites containing SiO2 and plasma-treated carbon fibers improved obviously.

Unidirectional carbon fibre reinforced poly (vinylidene fluoride): Impact of atmospheric plasma on composite performance

A powder impregnation process with integrated inline continuous atmospheric plasma fluorination (APF) of carbon fibres to produce unidirectional carbon fibre/polyvinylidenefluoride (PVDF) tapes with a fibre volume fraction of 60% was developed. Carbon fibre/PVDF tapes were processed into test laminates by compression moulding and interface dominated composite properties were studied. The short beam strength of composites containing fluorinated carbon fibres improved by up to 200%. Flexural strength and modulus of laminated carbon fibre/PVDF composites containing APF treated carbon fibres increased by 110% and 37.5%, respectively. Critical energy release rate at initial crack determined using Mode I (DCB) and Mode II (ENF) tests for composites containing fluorinated carbon fibres exhibited about four times and two times enhancement, respectively, over composites made with as-received carbon fibres. Essential and non-essential work of fracture of composites containing fluorinated carbon fibres determined using the trousers test increased by 140% and 104%, respectively.

Impact of in‐line atmospheric plasma fluorination of carbon fibers on the performance of unidirectional, carbon fiber‐reinforced polyvinylidene fluoride

AbstractUnidirectional, carbon fiber‐reinforced polyvinylidene fluoride (PVDF) composites were manufactured using a powder impregnation process with integrated in‐line continuous atmospheric plasma fluorination of carbon fibers to produce unidirectional carbon fiber/PVDF tapes with a fiber volume fraction of 60 ± 2%. Carbon fiber/PVDF tapes were processed into composite laminate test specimens by compression moulding and interface‐dominated composite properties were studied. Short‐beam shear test results showed an improvement of up to 70% for the composite laminates containing atmospheric plasma‐fluorinated T700 carbon fibers with a fluorine content of 3.7 at. %, as determined by X‐ray photoelectron spectroscopy. The flexural strength and modulus of the laminated carbon fiber/PVDF composites containing APF‐treated T700 carbon fibers also increased by 45% and 38%, respectively. © 2010 Wiley Periodicals, Inc. Adv Polym Techn 29:86–97, 2010; Published online in Wiley InterScience (www.interscience.wiley.com). DOI 10.1002/adv.20175

A model for thermoplastic melt impregnation of fiber bundles during consolidation of powder-impregnated continuous fiber composites

Continuous fiber thermoplastic matrix composites were fabricated using a novel powder-impregnation process that combined vacuum assisted resin transfer molding (VARTM) with compression molding. The resulting composite has an average fiber volume fraction of 65%. A model has been developed for the consolidation phase to predict the void fraction of the resulting composite. This model takes into account the fabric unit cell dimensions and material properties and assumes that tow permeability remains constant. The model is compared to experimental values for void fraction for samples prepared using a range of consolidation pressures and dwell times.

Microstructure of ceramic particles infiltrated into float glass surfaces by high gas pressure impregnation

Glass–ceramics were produced by impregnation of powders onto a surface under pressure. Samples of four classes of oxide powders (SnO 2, Co 3O 4, TiO 2and Al 2O 3) were infiltrated into a commercial float glass substrate. These powders were impregnated on the glass surface under high gas pressure (16–18 atm) and below the T g temperature in a specially designed pressurized chamber to form M x O y –SiO 2 films. The phases were analyzed by X-ray diffraction (XRD), and the results reveal the structure and crystallinity of the selected oxide powders as prepared and after inclusion in the glass substrate. The formation of films by the proposed method is viable due to the mean particle size of the powders deposited on the glass surface. Differences in the surface morphology of glass–ceramics films were attributed to the morphology of the powders used for impregnation. The formation mechanism of M x O y –SiO 2 films was based on compositional differences in the glass substrate before and after the powder impregnation process and on their surface morphology.

Manufacture of aramid fibre reinforced nylon-12 by dry powder impregnation process

The present paper deals with the manufacturing of composites, consisting of continuous aramid fibres and nylon-12, by applying the so-called dry powder impregnation process. The fibres are pre-impregnated by the deposition of fluidised powder particles on aramid fibre tows which are consolidated by heat and pressure to form continuous prepregs. Features of the nylon-12 powders which are important for the dry powder impregnation process are discussed. Material, tool and processing parameters influencing the achievement of impregnation and therefore the fibre volume content of the prepregs are outlined.

Effects of Processing Variables on the Powder Impregnation Technique for Continuous Fibre Composite Materials

Prepregs of continuous glass fibre reinforced thermoplastics were produced, applying different processing variables of the powder impregnation process. The investigation was concerned with the effects of tow tension, line speed and temperature. A recently developed process model was employed to interpret the effects of temperature and fibre volume fraction on void content. An equation was derived to calculate fibre volume fraction according to the width of a spread fibre tow. Experimental results demonstrate that the process variables greatly affect the fibre content and the void content of the prepregs. The unidirectional prepregs of polyphenylene sulphide were laminated by hot-pressing. The flexural and shear strengths of the laminates are disproportionate to the void content of the prepregs, and the laminates.

Effects of Processing Variables on the Powder Impregnation Technique for Continuous Fibre Composite Materials

Prepregs of continuous glass fibre reinforced thermoplastics were produced, applying different processing variables of the powder impregnation process. The investigation was concerned with the effects of tow tension, line speed and temperature. A recently developed process model was employed to interpret the effects of temperature and fibre volume fraction on void content. An equation was derived to calculate fibre volume fraction according to the width of a spread fibre tow. Experimental results demonstrate that the process variables greatly affect the fibre content and the void content of the prepregs. The unidirectional prepregs of polyphenylene sulphide were laminated by hot-pressing. The flexural and shear strengths of the laminates are disproportionate to the void content of the prepregs, and the laminates.