Thermoplastic Research Articles

Evaluation of Fungal Decay and Biodegradation of Thermoplastic Composites Reinforced with Date Palm Fibres

Evaluation of Fungal Decay and Biodegradation of Thermoplastic Composites Reinforced with Date Palm Fibres

Compression Molding of Low-Density Polyethylene Matrix/Glass-Fiber-Reinforced Thick Laminates.

Thermoplastic fiberglass was compression molded in the form of thick panels with a nominal thickness of 10 mm and a size of 300 × 300 mm2. A simplified procedure was adopted to speed up the lamination procedure and adapt it to the aim of recycling waste, glass fibers, fabrics, and thermoplastic films. Low density polyethylene was used as a matrix to simplify the laboratory process, but the same procedure can be extended to other thermoplastic film, such as polyamide. The final thermoplastic composite shows unique properties in terms of its repairability, and its performance was improved by increasing the number of repairing repetitions. For this aim, a repairability test was designed in the bending configuration, and three consecutive cycles of bending/repairing/bending were carried out. The static mechanical properties of the final thermoplastic composite were, conversely, low in comparison with traditional fiberglass because of the choice of a polyethylene matrix. The bending tests showed that the maximum strength was lower than 10 MPa and the elastic modulus was less than 1 GPa. Nevertheless, the toughness of the thermoplastic composite was high, and the samples continued to deform under bending without splitting into two halves.

Base-free trifluoroacetylation: From methyl glucopyranoside to cellulose nanofibers

Trifluoroacetic anhydride (TFAA) reacts smoothly with low molecular weight carbohydrates and cellulose nanofibers (CNFs) under base-free conditions. Methyl α- and β-d-glucopyranoside were used as model compounds to optimize reaction conditions, which were then applied to lyophilized CNFs for surface modification. ATR-IR spectroscopy and powder X-ray diffraction were employed to characterize the modified CNFs. Trifluoroacetylation for 4 h yields a degree of substitution (DS) of 0.4 acyl groups per anhydroglucose unit while maintaining a crystallinity index near 50 %. DS values were quantified by gravimetry, acid–base titration after saponification, and a novel approach utilizing solution 19F NMR spectroscopy which offers greater accuracy than the other techniques. This study presents an efficient, base-free method for derivatizing carbohydrates as well as surface functionalization of CNFs with trifluoroacetyl groups, potentially expanding their application in fiber-reinforced thermoplastic composites.

The Effects of Laser-Assisted Winding Process Parameters on the Tensile Properties of Carbon Fiber/Polyphenylene Sulfide Composites.

Currently, there is limited research on the in situ forming process of thermoplastic prepreg tape winding, and the unclear impact of process parameters on mechanical properties during manufacturing is becoming increasingly prominent. The study aimed to investigate the influence of process parameters on the mechanical properties of thermoplastic composite materials (CFRP) using laser-assisted CF/PPS winding forming technology. The melting point and decomposition temperature of CF/PPS materials were determined using DSC and TGA instruments, and based on the operating parameters of the laser-assisted winding equipment, the process parameter range for this fabrication technology was designed. A numerical model for the temperature of laser-heated CF/PPS prepreg was established, and based on the filament winding process setup, the heating temperature and tensile strength were simulated and tested. The effects of process parameters on the heating temperature of the prepreg and the tensile strength of NOL rings were then analyzed. The non-dominated sorting genetic algorithm (NSGA-II) was employed to globally optimize the process parameters, aiming to maximize winding rate and tensile strength. The results indicated that core mold temperature, winding rate, laser power, and their interactions significantly affected mechanical properties. The optimal settings were 90 °C, 418.6 mm/s, and 525 W, achieving a maximum tensile strength of 2571.51 MPa. This study provides valuable insights into enhancing the forming efficiency of CF/PPS-reinforced high-performance engineering thermoplastic composites.

Effect of surface treatment on interface properties of carbon fiber reinforced PA6 composites during overmolding

AbstractCarbon fiber‐reinforced thermoplastic composites have the advantages of lightweight and high strength and have broad application prospects in automotive lightweighting. This study uses the Overmolding process to mold carbon fiber‐reinforced nylon 6 composite materials. By using laser surface treatment and preheating technology, the interfacial bonding performance of the composite material is emphasized. By optimizing the embedding temperature, it was observed that the in‐plane shear strength increased by 13 times to 70 MPa, and the tensile strength increased by 10 times to 44 MPa. Similarly, by adjusting the melting temperature, the in‐plane shear strength was significantly improved, and the mechanical interlock and interfacial bonding were effectively enhanced by laser surface treatment, achieving the same effect as embedding preheating. By establishing a finite element model, the in‐plane tensile and in‐plane shear at the interface were accurately simulated, and the progressive failure process of the interface layer was successfully predicted.Highlights Laser energy density strengthens the overmolding interface. Optimizing insert, mold, and melt temperatures enhances interface bonding. Shear and tensile tests reveal differences in interface failure behavior. Finite element model accurately simulates overmolding interface failure. Laser treatment and temperature control are key to stronger interfaces.

Modelling the time-dependent mechanical properties of thermoplastic and thermosetting polymers with Gumbel distribution functions

In this paper, we propose a simple modelling method that accurately describes the time-dependent viscoelastic behaviour of thermoplastic and thermosetting solid polymers. We performed short-term creep and stress relaxation tests on representative samples of three major classes of polymers: an amorphous, a semi-crystalline thermoplastic and a thermosetting polymer. Then, to investigate the relationship between the model parameters and the material composition, we also tested thermoplastic matrix composites with different plasticiser contents. From the short-term tests, master curves were constructed with the use of the time–temperature superposition principle. Then, the temperature dependence of the obtained shift factors was described using the Arrhenius model. The resulting creep compliance and relaxation modulus master curves were normalised and modelled with a two-parameter cumulative Gumbel distribution function (CDF) and its complementary distribution function (CCDF). For the creep and stress relaxation master curves, the median error of modelling was less than 16 % and 16.5 % in all cases, respectively. Furthermore, it was less than 2 % for the thermosetting polymer, making this model an excellent tool for describing the creep and stress relaxation behaviour of thermosetting systems. In the case of the plasticised composites, we found a strong relationship between the material composition and the location parameter of the Gumbel model. Based on this, we developed a method that can be used to estimate the evolution of the creep compliance curve for any arbitrary OLA content (between 0 wt% and 16 wt%) at any desired temperature (between 22 °C and 70 °C).

Evaluation of foaming performance for polymer modified and virgin asphalt binders

The pavement suffers rapid deterioration as a result of the weak bonding strength exhibited by the foamed virgin asphalt in the mixture. Consequently, it is crucial to develop a modified asphalt suitable for foaming. The expansion height and bubble size of foamed asphalt can be continuously and simultaneously monitored by binocular ranging equipment. By analyzing these dynamic responses, the evolution of the spatial domain expansion characteristics and the geometric features of the surface bubbles of foamed thermoplastic resin modified asphalt (TRA) was analyzed. Meanwhile, multi-stress creep recovery (MSCR) and bending beam rheometer (BBR) tests were conducted to analyze its rheological properties. Subsequently, the dispersibility of foamed TRA in the mixture was explored. The results showed that thermoplastic resin significantly improved the physical performance stability of foamed asphalt, as evidenced by an increase in its half-life by 2–3 times compared to the virgin asphalt when the dosage of thermoplastic resin reached 8 %. Foamed modified asphalt has fewer bubbles, but it has larger bubble sizes and more uniform distribution of bubbles. Meanwhile, the TRA exhibited excellent high-temperature deformation resistance and elastic recovery ability. The dispersion uniformity of foamed TRA in the mixture was superior to that of virgin asphalt. This study serves as a valuable reference for the exploration of foaming behavior in modified asphalt and the utilization of foamed modified asphalt in the mixture.

Enhanced mechanical, thermal, water and UV aging resistance properties of bamboo fiber/HDPE composites through silane coupling agent modified nano-SiO2-TiO2

Nano-TiO2 is widely employed to enhance the properties of plant fiber reinforced thermoplastic polymer composites due to its chemical inertness, anti-aging, and anti-bacterial properties. However, the enhancement of bamboo fiber/high-density polyethylene (BF/HDPE) composites is limited by the high photocatalytic activity of nano-TiO2 and its poor compatibility with the BF/HDPE matrix. This study employs an organic-inorganic co-modification to prepare BF/HDPE composites reinforced with silane coupling agent KH550 modified nano-SiO2 coated nano-TiO2 (KH550/SiO2-TiO2) by spray coating and melt mixing methods, and the properties of the composites were tested and characterized. The effects of KH550 and KH550/SiO2-TiO2 content on the properties of modified BF/HDPE composites, including mechanical properties, water absorption, thickness swelling rate, water contact angle, thermal stability, and UV aging resistance，which were characterized using methods of mechanical tests, FTIR, UV-Vis, XPS and SEM, both before and after modification. The results indicate that KH550 effectively improves the agglomeration phenomenon and enhances the dispersibility of nano-SiO2-TiO2 in the BF/HDPE composites. The optimal thermal stability is achieved when the BF/HDPE composites modified with a 5 wt% KH550/SiO2-TiO2, while BF/HDPE composites modified with a 3 wt% KH550/SiO2-TiO2 exhibit the better mechanical properties, water resistance, and UV aging resistance compared to other contents. Flexural strength and modulus of KH550/SiO2-TiO2 modified BF/HDPE composites increased by 18.71 % and 17.92 %, tensile strength and modulus increased by 7.74 % and 21.92 %, respectively. The 480-hour water absorption and thickness swelling rate decreased by 18.68 % and 20.73 %, respectively, and the contact angle increased by 19.17°; better thermal stability and color stability was observed. The spray coating method was more effective in improving the properties of the modified BF/HDPE composites than the melt mixing method. Comprehensive analysis indicates that the mechanical properties, water resistance, thermal stability, and UV aging resistance of the BF/HDPE composites reinforced with 3 wt% KH550/SiO2-TiO2 prepared by the spray coating method are significantly enhanced.

Effect of geometry and adhesion on the performance of fiber reinforced thermoplastic composite joints with metal inserts

Joints for laminated composite structures using mechanical fasteners or adhesives often face issues such as reduced strength from fiber breakage in mechanically fastened joints and complex preparation for adhesive joints. Additionally, adhesive joints require compatibility between the adhesive and the composite matrix, limiting their suitability for many thermoplastics. To address these challenges, this study explores a technique that uses metal inserts embedded during the consolidation of laminated thermoplastic composites. It investigates how the geometry of metal inserts and their adhesion to the fiber-reinforced thermoplastic composite affect the joint’s performance under out-of-plane loads. Results indicate that while mechanical locking assists in load transfer, the adhesion between the metal insert and the composite is crucial for the joint’s failure mechanism and overall performance. Strong adhesion delays final failure by requiring fiber breakage through the composite’s entire thickness, while weak adhesion leads to failure through fiber breakage on the bearing side.

A comparative experimental work on the drop-weight impact responses of thermoplastic polymers produced by additive manufacturing: combined influence of infill rate, test temperature, and filament material

A comparative experimental work on the drop-weight impact responses of thermoplastic polymers produced by additive manufacturing: combined influence of infill rate, test temperature, and filament material

Weld quality monitoring in friction stir lap joining of dissimilar Al6061 to polycarbonate using thrust–torque-based process stability signatures

The joining of dissimilar aluminium-based alloys to thermoplastic polymers is highly challenging which indicates the necessity of friction welding procedures. The present work addresses the degrees of steadiness in welding thrust-torque to monitor the lap weld contour of aluminium alloy (Al6061) overlapped on polycarbonate sheet or vice versa using friction stir welding. The primary objective was to compare the monitoring capability of the weld non-uniformity by using raw signals and stability signature of welding thrust and stirring torque. Further, these stability indices were used for the prediction of weld mechanical behaviour using response surface methodology. The stability signatures were found to be a better indicator of weld profile unevenness than raw signals as it was an amplified version of the local deviations in welding thrust-torque. Improved strength efficiency up to 49% was noticed in PC-Al welds due to improved process stability at intermediate tool traverse (55 mm/min) and revolving speeds (1100 rpm). The stability in stirring torque was better indicator of weld quality features than tool thrust steadiness in Al-PC lap while it was reversed in PC-Al lap. Thus, the thrust force instability was mostly indicated the joint ductility while combined steadiness in thrust-torque were essential for the prediction of weld strength. The higher stability index in tool thrust (≥7.5) with ample torque steadiness (5–8) can upgrade the Al-PC weld strength (≥20 MPa), whereas intermediate thrust stability (6–6.5) with high stable torque (≥7) can uplift the joint strength (≥25 MPa) in PC-Al welds.

The Influence of Diatomite on the Sound Absorption Ability of Composites.

Diatomites are well-known mineral materials formed thousands of years ago from the skeletons of diatoms. They are found in many places around the world and have a wide range of applications. This article presents innovative research related to the possibility of using diatomite as a filler in composites to improve their sound absorption properties. The results of the study of the effect of diatomite processing (calcination) and its degree of fineness on the sound absorption coefficient of thermoplastic composites are presented. Three fractions of diatomite (0 ÷ 0.063 mm; 0.5 ÷ 3 mm; 2 ÷ 5 mm) and its variable mass proportion (0, 25, and 50 wt.%) were used. The composites were made with flax fibers as a reinforcement, polylactide as a matrix, and diatomite as an additional filler. This paper also presents the results of oxide chemical composition, diatomite mineral phase composition, morphology, and thermal conductivity coefficient of all diatomite fractions studied. In addition, the average particle size for diatomite powder was also determined. The most important of the studies was the determination of the acoustic properties of the aforementioned composites. As a result of the tests, it was found that the smallest fraction of diatomite particles and a variant without thermal treatment give the best effect in terms of sound absorption.

Impact of graphite on tribo‐mechanical, structural, and thermal behaviors of polyoxymethylene copolymer/glass fiber hybrid composites via Taguchi optimization

AbstractUnique hybrid thermoplastic composites based on polyoxymethylene copolymer (POM C), 10 wt.% glass fiber (GF) and graphite (Grt) filler at 1, 3, and 5 wt.% were developed using injection molding technique. According to the Taguchi L16 orthogonal array, present experiments were carried out with the aim of determining the coefficient of friction (COF) and specific wear rate (SWR) under a range of loads (namely, 5, 10, 20, and 30 N), sliding speeds (namely, 200, 400, 600, and 800 rpm), and run times (namely, 15, 30, 45, and 60 min) with varying wt.% of Grt (namely, 1, 3, and 5 wt.%) throughout the experiment. Analysis of variance (ANOVA) was used to evaluate the most significant factors that affect the output functions (viz., COF and SWR). The findings demonstrated that POM C/10GF composites' tribo‐mechanical, structural, and thermal properties were considerably improved upon by including Grt. Various microscopical methods were also employed to study the wear mechanisms of the composites and the surface morphology of the worn samples. The POM C/10GF with a 3 wt.% of Grt exhibited superior tribological properties owing to its enhanced interfacial bonding characteristics, resulting to increased wear resistance.Highlights Injection molded POM C/10GF hybrid composites with 1, 3, and 5 wt.% graphite (Grt) Structural, thermal, chemical, tribo‐mechanical and microstructural studies Design of experiment with variable loads, times, speeds, and Grt compositions COF and specific wear resistance as response Optimization of hybrid composite composition using Taguchi L16 orthogonal array

3D printing single‐stroke path planning, local reinforcement and performance testing of MBB beams and cantilever beams

Abstract3D printing of continuous fiber reinforced thermoplastic composites (CFRTPCs) has been applied for the molding of composite complex structures due to the advantages of flexibility and one‐step forming. In this study, feature points simplification, merging and rearrangement were accomplished for Messerschmitt‐Bölkow‐Blohm (MBB) beam and cantilever beam to generate single‐stroke print paths for the specimens. For the significant stress areas in the finite element analysis results of these structures, a local reinforcement method using orthogonal layups was proposed, which was achieved by raising and lowering the print head and adjusting the fiber volume fraction during the printing. After experimental validation and failure modes analysis, the path planning significantly improved the peak load and structural stiffness of the specimens, and the local reinforcement further enhanced the equivalent specific strength and specific stiffness. This study provides a single‐stroke 3D printing strategy for complex structure molding in conjunction with parameter adjustments.Highlights A single‐stroke path planning was developed for MBB beams and cantilever beams, including simplification, merging and rearrangement methods for feature points. A local reinforcement method was proposed, which was achieved by raising and lowering the print head and adjusting the fiber volume fraction during the printing process. The effect of different print paths on specimen properties was investigated.

Effect of High Fiber Content on Properties and Performance of CFRTP Composites

Continuously reinforced thermoplastic composites are widely used in structural applications due to their toughness, light weight, and shorter process cycle. Moreover, they provide flexibility in design and material selection. Unlike thermoset composites, continuous fiber content to maximize mechanical properties in thermoplastic composites has not been well investigated. In this paper, three thermoplastic systems are investigated to study the optimum content of continuous fiber reinforcement. These systems include carbon fiber/polyphenylene sulfide (PPS), glass fiber/PPS, and glass fiber/high-density polyethylene (HDPE). Tapes were made at several fiber contents, and samples were compression molded and tested using thermo-gravimetric analysis (TGA), differential scanning calorimetry (DSC), dynamic mechanical analysis (DMA), tensile, 3-point flexure, and short-beam shear tests. Results revealed that higher fiber content led to an increase in the glass transition and melt transition temperatures of the polymer. Some mechanical properties increased with fiber content and then began to decrease upon further addition of fibers, while other properties, such as ductility and interfacial bond strength, decreased with more reinforcement. Furthermore, the optimum fiber contents to maximize mechanical properties are different for different properties and different materials.

Reliability of two-dimensional steady magnetized Jeffery fluid over shrinking sheet with chemical effect

Abstract A numerical framework is established for a two-dimensional steady flow of the magnetized Jeffery fluid model over elongated/shrinking sheets, with potential applications such as coating sheets, food products, fiber optics, drilling fluids, and the manufacturing processes of thermoplastic polymers. The model also demonstrates the influence of chemical reaction, magnetic field, and stability analysis which provide a novel contribution to this study. To ensure the ease and effectiveness of this analysis, we transform the set of difference equations governing the system into ordinary equations using the similarity transformation. The reliability of the solution is examined by using stability analysis. The Navier–Stokes equations have been transformed into self-similar equations by adopting appropriate similarity transformations and subsequently solved numerically using the bvp4c (three-stage Labatto-three-A formula) approach. The comparison between the derived asymptotic solutions and previously documented numerical results is quite remarkable. The self-similar equations display a duality of solutions within a limited range of the shrinking parameter, as observed from the data. For each stretching scenario, there is a unique solution. Hence, an examination of temporal stability has been conducted through linear analysis to establish the most fundamentally viable solution. The determination of stability in the analysis is based on the sign of the smallest eigenvalue, which indicates whether a solution is unstable or stable. The analysis of stability reveals that the first solution, which describes the primary flow, remains stable. Through the utilization of graphs, we thoroughly examine and discuss the influence of emerging factors. The numerical results obtained from this analysis demonstrate multiple solutions within a certain range of M 1 ≥ M ci {M}_{1}\ge {M}_{{ci}} , i = 1 , 2 , 3 i=1,2,3 , and no solution in the range M 1 < M ci {M}_{1}\lt {M}_{{ci}} . M ci {M}_{{ci}} denotes the critical values, which increase as the quantities of Sc {\rm{Sc}} increase from 0.3 to 0.9. Similarly, multiple solutions exist for λ ≥ λ ci \lambda \ge {\lambda }_{{ci}} , i = 1 , 2 , 3 i=1,2,3 , and no solution in the range λ < λ ci \lambda \lt {\lambda }_{{ci}} is observed.

Realizing ultrahigh strength and excellent stability of ultrasonically welded joints upon co-consolidating an extra resin layer (eRL) on the thermoplastic composites

Ultrasonic welding is a promising technique well-suited for joining thermoplastic composites. On the way towards upscaling and industrializing this technology, it is crucial to improve the welding process stability and joint structure integrity. Herein, a novel-structured carbon fiber (CF)/polyetherimide (PEI) composite topped with an extra PEI resin layer was developed using a co-consolidation process for ultrasonic welding. The experimental results proved that the extra resin layer effectively promoted the heat generation efficiency at the joining interface, improved the quality and uniformity of the welding line, as well as played a thermal barrier role to prevent composite overheating. This significantly improved the welding stability and the mechanical performance of the joints. For example, a superior lap-shear strength of 45.9 MPa was obtained by simultaneously optimizing the thicknesses of the extra resin layer and the energy director. Moreover, the bending and squeezing-out of carbon fibers at the welding interface were successfully eliminated.

A semi-analytical model for low-density impact-based surface treatments: Application to the abrasive waterjet texturing of thermoplastic polymers

Surface roughness is critical for bonding applications, as it directly influences the mechanisms occurring at the adhesive interface. Abrasive Waterjet texturing has emerged as a promising technique for functionalizing surfaces, but predicting the surface characteristics from stochastic impact-based processes remains a challenge. This study aimed to develop a numerical model capable of forecasting key morphological parameters for AWJ-textured surfaces with pilotable treatment coverage. The proposed model was optimized through theoretical analysis and confronted to topographical data from polymer samples treated with low-density AWJ using standard parameters. Profilometry measurements were supported by a custom post-treatment algorithm to remove artefacts and assess the characteristics of individual particle impacts (number, repartition, dimensions). The predicted roughness showed a 94 % concordance to the measured values.

Tensile, flexural and fatigue properties of different thermoplastic nanocomposites: experimental investigation and ANN prediction of the fatigue life

ABSTRACT Polymer-based nanocomposites have received immense attention in industrial applications as their mechanical properties are superior to traditional polymer composites. In this study, three different thermoplastic polymers, namely (a) polypropylene (PP), (b) acrylonitrile butadiene styrene (ABS), and (c) high-density polyethylene (HDPE) were used for the purpose of engineering different nanoclay-based nanocomposites. The blending of the polymer was performed by varying the nanoclay weight percentage (0.5, 1, 3, and 5 wt.%) using a twin-screw extruder. The different nanocomposites were fabricated through injection moulding process. The composites were fabricated by considering the 90 bars of injection pressure, 60 mm/s of injection speed, and 25 sec of cooling time. The effect of nanoclay inclusion on the mechanical properties of the nanocomposites was evaluated and compared with the neat polymer. The effect of nanoclay inclusion was studied through morphological analysis of the fractured tested specimens. The tensile strength and modulus of ABS-nanoclay (5%) exhibited an enhancement of 30.95% and 35%, respectively as compared to the pure ABS. Meanwhile, the fatigue life revealed an improvement of 66.01%. The tensile strength and modulus of the ABS/nanoclay (5%) were achieved as 38.6 MPa and 1.44 GPa.

Experimental investigation on low‐velocity impact performance of carbon fiber reinforced polyether ether ketone thermoplastic composite materials in room and elevated temperature

AbstractCarbon fibers woven‐ply reinforced polyether ether ketone (C/PEEK) thermoplastic composites are widely used in aerospace and high‐tech industries because of their exceptional resistance to low‐velocity impact. In this paper, experimental investigation is carried out to determine the low‐velocity impact performance of C/PEEK laminates at room temperature (RT) and high temperature (90°C and 150°C) environments. Both macroscopic and microscopic analyses are applied to examine the influence of temperature on the mechanical response and damage mode of the material. The attention of this investigation is on impact parameters such as maximum contact force, energy absorption rate, indentation depth, and damage mode. The findings show significant changes in material stiffness, rate of energy absorption, and indentation depth with rising temperature. Temperature variations have a notable effect on the PEEK matrix plasticity, C/PEEK composite interlaminar properties, crack initiation and propagation, and damage mode at the overlaps of warp and weft fibers, resulting in a transition from brittle to ductile failure.Highlights Experimental investigation is carried out to study the low‐velocity impact performance of C/PEEK. The effects of impact energy and environmental temperature on the low‐velocity impact performance of C/PEEK are investigated. The mechanism of how environmental temperature affects the damage mode of C/PEEK is investigated.