Fiber-reinforced Thermoplastic Composites Research Articles

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

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

Achieving gradual failure under bending by the layering design of 3D printed continuous fiber reinforced composites

A variety of methods have emerged to tailor the mechanical properties of 3D-printed continuous fiber-reinforced thermoplastic composites (CFRTCs) through geometry design or manufacturing parameters. However, the potential to achieve customized failure behavior is not exploited. In this study, the effect of different layer orders on load bearing and failure of 3D-printed CFRTCs is investigated. Carbon fiber-reinforced polyamide composites with six layer orders were prepared and the mechanical response in 4-point bending was investigated. We show that the failure behavior ranges from catastrophic to pseudo-ductile, and we distinguished four typical stress-strain responses. We found that the location and the thickness of matrix-only layers strongly influence the failure. For the latter, we present a linear relationship to the ductility index which shows that toughness can be increased with thicker matrix layers. Our results facilitate the design of CFRTCs with customizable failure behavior, thus contributing to safer applications.

Optical properties optimization of carbon fiber reinforced thermoplastic tapes by micro surface texturing for enhanced laser heating efficiency and in-situ consolidation quality during AFP process

The laser-assisted automated fiber placement (L-AFP) process of carbon fiber-reinforced thermoplastic composites suffers from insufficient heating efficiency and in-situ consolidation quality caused by significant reflection on the tape surface. Here, we propose a novel strategy to increase the heating efficiency by refocusing the reflected light, initially scattered to the environment and wasted, onto the tapes for multiple and full absorptions. The method for laser concentration is first validated through light-tracing simulation. Then, three kinds of tapes with different micro textures on the surface are prepared by the hot-embossing process. The transverse V-grooved texture tapes and flat surface tapes absorb 25% more laser energy than the longitudinal V-grooved and commercial tapes due to the reduction in transverse scattering angle from 180° to 2.72°. This leads to a temperature increase of 130 °C at the nip point during the L-AFP process at the lay-down rate of 500 mm/s with 1 kW laser power. Improved in-situ consolidation quality leads to a significant increase in the flexural and shear strength of L-AFP-prepared carbon fiber reinforced polyetheretherketone (CF/PEEK) laminates, with a reduction in porosity to around 2%.

Toward a circular economy: zero-waste manufacturing of carbon fiber-reinforced thermoplastic composites

Fiber-reinforced composites are becoming ubiquitous as a way of lightweighting in the wind, aerospace, and automotive industries, but current recycling technologies fall short of a circular economy. In this work, fiber-reinforced composites made of recycled carbon fiber and polyphenylene sulfide were recycled and remanufactured using common processing technologies such as compression and injection molding. An industrially viable size-exclusive sieving technique was used to retain fiber length and reduce variability in the mechanical properties of the remanufactured composites. Fiber length reduction alone could not explain the strength reductions apparent in the composites, which we propose are due to microstructural inhomogeneity as defined by poor dispersion of the fibers. Future recycling efforts must focus on fiber length retention and good dispersion to make composite remanufacturing a viable path toward a circular economy.

Exceptional mechanical performance by spatial printing with continuous fiber: Curved slicing, toolpath generation and physical verification

This work explores a spatial printing method to fabricate continuous fiber-reinforced thermoplastic composites (CFRTPCs), which can achieve exceptional mechanical performance. For models giving complex 3D stress distribution under loads, typical planar-layer based fiber placement usually fails to provide sufficient reinforcement due to their orientations being constrained to planes. The effectiveness of fiber reinforcement could be maximized by using multi-axis additive manufacturing (MAAM) to better control the orientation of continuous fibers in 3D-printed composites. Here, we propose a computational approach to generate 3D toolpaths that satisfy two major reinforcement objectives: (1) following the maximal stress directions in critical regions and (2) connecting multiple load-bearing regions by continuous fibers. Principal stress lines are first extracted in an input solid model to identify critical regions. Curved layers aligned with maximal stresses in these critical regions are generated by computing an optimized scalar field and extracting its iso-surfaces. Then, topological analysis and operations are applied to each curved layer to generate a computational domain that preserves fiber continuity between load-bearing regions. Lastly, continuous fiber toolpaths aligned with maximal stresses are generated on each surface layer by computing an optimized scalar field and extracting its iso-curves. A hardware system with dual robotic arms is employed to conduct the physical MAAM tasks depositing polymer or fiber reinforced polymer composite materials by applying a force normal to the extrusion plane to aid consolidation. When comparing to planar-layer based printing results in tension, up to 644% failure load and 240% stiffness are observed on shapes fabricated by our spatial printing method. We demonstrate the versatility of our approach through various complex load cases which demonstrate their successful implementation of continuous fiber printing in 3D.

Non-contact heating methods of carbon fiber thermoplastic composites based on Joule thermal properties: Optimization and validation

Carbon fiber matrix composites have garnered significant attention due to their exceptional properties, finding wide-ranging applications in industries such as aerospace, transportation, and military. In this study, a novel approach involving the addition of nickel was explored to fabricate carbon fiber-reinforced thermoplastic polymer composites and composite materials filled with nylon 12, utilizing nickel foam as matrix. Subsequently, electromagnetic-thermal multiphysics coupling models were established to analyze the induction heating process. The study investigated the effects of nickel content, spatial location of the main heat source, coil current, and coil frequency on the temperature rise and heat generation. Additionally, a linear fit was applied to determine the material surface temperature and related factors during induction heating. Furthermore, a theoretical formula was derived for induction heating under ideal conditions, elucidating the heat transfer mechanism and the influence of various factors on heat generation. The findings of this research serve as a reference for optimizing the utilization of Joule heat in composites, thereby expanding the application of carbon fiber-reinforced polymer composites in temperature regulation and operational control.

Study on self-healing mechanism of magnetic nano-powders functionalized fiber reinforced thermoplastic composites

At present, a variety of methods have been developed to realize the self-healing function of fiber-reinforced composites. However, the intrinsic mechanism of material damage recognition and self-healing initiation still lacks systematic research. In this paper, GF/(FeNip/PP) composites with multistage structures were prepared to study the self-healing properties and the mechanism of fiber-reinforced thermoplastic composites. The addition of a small amount of FeNip without affecting the melting peak temperature of the PP matrix (i.e., without reducing the use temperature of PP) can increase the electromagnetic loss (tanδ) of the composites by about 40% and the thermal conductivity by 36%. The cyclic stretching times of GF/(FeNip/PP) composites after microwave healing are doubled at 50% to 60%σmax load. It is indicated that FeNip endows the GF/PP composites with good microwave healing performance, and the purposeful repair can effectively extend the service life of the material. In addition, the self-healing mechanism of GF/(FeNip/PP) composites is discussed in detail from the aspects of microstructure change, multiphase interface effect, entropy enthalpy effect, starting and ending of self-healing procedures, etc. The magnetothermal effect, “entropy consumption” effect, and polymer chain diffusion are the fundamental reasons for the self-healing function of fiber reinforced thermoplastic composites.

Investigating the mechanical properties of 3D fused deposition modeling composites reinforced with continuous fibers: Effects of fiber number and negative Poisson structure

The use of 3D printers is expanding across various industries. The incorporation of reinforcing fibers and structures, such as negative Poisson, has the potential to enhance the mechanical properties of three-dimensional products. In this study, a specialized nozzle is developed for 3D Fused Deposition Modeling (FDM) printers dedicated to the production of continuous fiber-reinforced thermoplastic (CFRT) composites. The primary objective is to enhance the tensile strength and impact resistance of 3D-printed samples. It is achieved through the investigation of strategies such as fiber reinforcement, variation in the number of fibers within the reinforcing yarn, and the creation of samples featuring an internal structure with a negative Poisson’s ratio (NPRS). In this regard, four types of 3D samples are prepared including polymer only, polymer with a negative Poisson’s ratio structure, polymer reinforced with continuous fibers (glass and carbon fibers), and polymer reinforced with continuous fibers featuring a negative Poisson’s ratio structure. The mechanical properties of these samples, including tensile strength and impact resistance, are also compared. The results indicate that incorporating fibers as reinforcement can enhance the mechanical properties of 3D-printed products. Moreover, continuous fibers with more fibers within the same yarn count have an increased strengthening effect. The use of negative Poisson structures significantly improves impact resistance but adversely affects tensile strength.

Impact of weave architecture on the mechanical performance of carbon-aramid/PVB hybrid composites

Continuous fiber-reinforced thermoplastic composites having superior mechanical properties are preferred for lightweight architectures. Rising demands for enhanced mechanical performance under certain types of loadings have focused researchers toward the hybridization of composite materials. In this study carbon and aramid fibers were employed to produce hybrid fabrics by weaving in two different woven architectures, 1/1 plain and 2/1 twill. Polyvinyl butyral (PVB) matrix was reinforced with these woven fabrics and hybrid composites were fabricated by compression molding. Un-hybrid carbon and aramid composites were fabricated using PVB matrix, as control samples. Tensile characteristics of hybrid composites offered intermediate strain at failures of 0.5% due to the combined rigid and ductile natures of carbon and aramid, respectively. Flexural strength and absorbed impact energy (200 MPa and 97 kJ/m2) were higher for hybrid composites, and quick elastic recoveries were experienced in hybrid composites after impact. Plain woven reinforced hybridization had about 25% and 5% lower tensile and flexural characteristics respectively, as more interlocking zones of warp and weft yarns reduced strength. However, these interlocking zones positively contributed to impact performance by 11.5% higher energy absorption.

High injection molding welding strength and cross-sectional analysis of carbon fiber composite materials

In this study, carbon fibers, commonly used as reinforcement materials, were added to polyamide (nylon) PA6 to fabricate carbon fiber-reinforced thermoplastic composites (CFRTP), which were then subjected to injection molding welding. The aim of this research was to investigate the positive influence of carbon fibers on injection molding welding strength and explore the optimal injection conditions. Three different joining combinations and various injection parameters were examined. The tensile fracture surfaces after welding were observed using polarized microscopy and scanning electron microscopy. The reinforcing mechanism of carbon fibers was analyzed. Ultimately, the optimal conditions were determined as a mold temperature of 120°C, an injection temperature of 380°C, and an injection velocity of 150 mm/s. The addition of carbon fibers exhibited significant strengthening effects on the injection molded joints, and it also provided the potential for injection molding welding between resins with poor compatibility.

Robot-assisted laser additive manufacturing for high-strength/low-porosity continuous fiber-reinforced thermoplastic composites

Additive manufacturing (AM) of continuous fiber-reinforced thermoplastic composites (CFRTPCs) has become a hot area for both academia and industry. In this paper, a robot-assisted laser additive manufacturing (RLAM) technique is proposed, which involves utilizing a laser beam to heat the filament to a semi-molten state, followed by compacting it with a roller and bonding it layer by layer to create densely structured components. Firstly, an integrated framework of hardware, software, and control systems is presented. Then, the relationship between the processing parameters and the properties of the final specimens was examined. Finally, a process strategy was proposed to improve the forming accuracy. Due to the effective impregnation of continuous carbon fibers, the printed CFRTPCs using the LRAM process exhibit comparatively low porosity and superior mechanical performance. Specifically, the flexural strength, flexural modulus, and interlayer shear strength reached 584 MPa, 43.7 GPa, and 28.0 MPa, respectively. The prepared specimens boast a porosity of 0.19%, approaching levels achieved through autoclave processes. In addition, it was found that the dynamic offset of the yaw axis could be utilized to correct the deviation of the actual forming path due to the pultrusion force, thus making the position of the towpreg under the rollers controllable and improving the accuracy of the parts. This new method combines the advantages of industrial robotics and laser&roller-based continuous fiber additive manufacturing processes to enable high-performance additively manufactured large and complex CFRTPCs, which shows great potential for printing lightweight structures in the rail transit and aerospace industries.

Simulated end-of-life reuse of composites from marine applications using thermal reshaping of seawater-aged, glass fibre-reinforced acrylic materials

In this work, end-of-life reuse of continuous fibre-reinforced thermoplastic composites from marine applications has been simulated by thermally reshaping (reprocessing) seawater-aged materials. Specifically, resin-infused, V-shaped glass/acrylic composites were seawater-aged (60 °C; 170 h) and reprocessed in a heated hydraulic press (120 °C; 10 bar). Reprocessing promoted void collapse and increased short beam shear strengths. Unaged reprocessed materials retained 52 % and 57 % performance in flexural strength and modulus, (relative to virgin material), with corresponding retentions of 20 % and 62 % in the aged reprocessed materials, respectively. Ageing- and reprocessing-related flexural performance changes occurred due to mild matrix plasticisation and fibre misalignment, respectively.

Arris Composites develops carbon fiber reinforced composites to use in Brooks running shoes, presents Additive Molding, and develops flax fiber reinforced composites

On November 28, 2023, Arris Composites, a manufacturer with a technology reportedly enabling high-performing fiber-reinforced thermoplastic composites for mass-market products, announced a technology collaboration with Brooks Running during 2023 The Running Event (TRE) in Austin, TX (November 28 to 30).

Optimization of process parameters during flax and polypropylene composite manufacturing using Box-Behnken design of experiments

Composites produced from recyclable polymers are of greater scope in the industrial sector owing to their better quality, sustainability, and environmental considerations. In this study, flax fibre utilized as reinforcement and polypropylene fibre used as a matrix were used for producing thermoplastic composites. Flax/polypropylene needle punched non-woven was performed by a compression moulding process. Process parameters, temperature, time, and pressure were selected to optimize the flax/polypropylene (PP) production process using Box- Behnken Experimental Design (BBD) and response surface methodology. The effects of the process parameters on the material's tensile, flexural, and short beam shear strengths were studied. Furthermore, the research parameters were used to analyze of variance (ANOVA) and regression models for estimating the mechanical properties. Also, Scanning Electron Microscope (SEM) analyses were performed on the composites to study the surface morphologies in composites. The findings revealed that temperature was the ultimate cause influencing the mechanical properties, followed by pressure and time. Surface morphologies confirm the better bonding between the flax fibres and PP matrix. This work shall effectively choose the ideal values of process parameters for producing natural fibre-reinforced thermoplastic composites.

A Novel Combining Method for Composite Groove Structure Fabrication

A composite groove structure with high specific strength and light weight has great potential in industrial application, but few studies on this have been carried out due to the fact that it is difficult to fabricate by one of the existing methods. The purpose of this work was to propose a novel method combining 3D printing and filament winding to manufacture the groove structure and study the link between its mechanical strength needs and fabrication parameters. Specifically, filament winding and 3D printing were used to fabricate the cylinder part and complex ring slot part of the groove structure, which is difficult to fabricate by winding. The combining method took advantage of the winding’s high efficiency and the printing’s high forming degree of freedom. The specimen was taken from the structure and submitted to a short beam test to determine its interlaminar shear strength, whereas thermal tests were carried out to evaluate its mechanical performance under high temperature. The interlaminar shear strength reached 6.694 MPa at a fiber orientation of 90°, a heating temperature of 245 °C and a thickness of 0.5 mm. The SEM photo showed some voids and gaps and typical failure in the failed specimen. DMA and TGA were carried out to investigate the performance under high temperature, from which the storage modulus lost half to 120 °C. Overall, the proposed combining novel method offers a new direction in the fabrication of continuous fiber-reinforced thermoplastic composites’ groove structure.

A Comparative Study on the Mechanical Properties of Open-Hole Carbon Fiber-Reinforced Thermoplastic and Thermosetting Composite Materials.

In this paper, the damage initiation/propagation mechanisms and failure modes of open-hole carbon fiber-reinforced thermoplastic composites and thermosetting composites with tension, compression, and bearing loads are investigated, respectively, by experiments and finite element simulations. The experimental evaluations are performed on the specimens using the Combined Loading Compression (CLC) test method, the tensile test method, and the single-shear test method. The differences in macroscopic damage initiation, evolution mode, and damage characteristics between thermoplastic composite materials and thermosetting composite material open-hole structures are obtained and analyzed under compressive load. Based on scanning electron microscope SEM images, a comparative analysis is conducted on the micro-failure modes of fibers, matrices, and fiber/matrix interfaces in the open-hole structures of thermoplastic and thermosetting composites under compressive load. The differences between thermoplastic and thermosetting composites were analyzed from the micro-failure mechanism. Finally, based on continuum damage mechanics (CDM), a damage model is also developed for predicting the initiation and propagation of damage in thermoplastic composites. The model, which can capture fiber breakage and matrix crack, as well as the nonlinear response, is used to conduct virtual compression tests, tensile test, and single-shear test, respectively. Numerical simulation results are compared with the extracted experimental results. The displacement-load curve and failure modes match the experimental result, which indicates that the finite element model has good reliability.

Atomistic Modeling of the Effect of Temperature on Interfacial Properties of 3D-Printed Continuous Carbon Fiber-Reinforced Polyamide 6 Composite: From Processing to Loading.

The combination of continuous fiber-reinforced thermoplastic composites (CFRTPCs) and the continuous fiber 3D printing (CF3DP) technique enables the rapid production of complex structural composites. In these 3D-printed composites, stress transfer primarily relies on the fiber-resin interface, making it a critical performance factor. The interfacial properties are significantly influenced by the temperatures applied during the loading and forming processes. While the effect of the loading temperature has been extensively researched, that of the forming temperature remains largely unexplored, especially from an atomistic perspective. Our research aims to employ molecular dynamics simulations to elucidate the effect of temperature on the interfacial properties of continuous carbon fiber-reinforced polyamide 6 (C/PA6) composites fabricated using the CF3DP technique, considering both loading and forming aspects. Through molecular dynamics simulations, we uncovered a positive correlation between the interfacial strength and forming temperature. Moreover, an increased forming temperature induced a notable shift in the failure mode of C/PA6 under uniaxial tensile loading. Furthermore, it was observed that increasing loading temperatures led to the deterioration of the mechanical properties of PA6, resulting in a gradual transition of the primary failure mode from adhesive failure to cohesive failure. This shift in the failure mode is closely associated with the glass transition of PA6.

Experimental and Numerical Study of Healing Effect on Delamination Defect in Infusible Thermoplastic Composite Laminates.

The integrity of delaminated composite structures can be restored by introducing a thermally-based healing effect on continuous fiber-reinforced thermoplastic composites (CFRTPC). The phenomenon of thermoplastics retaining their properties after melting and consolidation has been applied by heating the delaminated composite plates above their glass transition temperature under pressure. In the current investigation, the composite is comprised of Methyl methacrylate (MMA)-based infusible lamination resin combined with benzoyl peroxide initiator, which polymerizes into a Polymethyl methacrylate (PMMA) matrix. For the reinforcement, unidirectional 220 gr/m2 glass filament fabric was used. Delamination damage is artificially induced during the fabrication of laminate plates. The distributed delamination region before and after thermally activated healing was determined by using non-destructive testing with active thermography. An experimental approach is employed to characterize the thermal healing effect on mechanical properties. Experimentally determined technological parameters for thermal healing have been successfully applied to repair delamination defects on composite plates. Based on the compression-after-impact (CAI) test methodology, the intact, damaged, and healed composite laminates were loaded cyclically to evaluate the healing effect on stiffness and strength. During the CAI test, the 3D digital image correlation (DIC) technique was used to measure the displacement and deformation fields. Experimental results reveal the difference between the behavior of healed and damaged specimens. Additionally, the numerical models of intact, damaged, and healed composite laminates were developed using the finite element code LS-Dyna. Numerical models with calibrated material properties and tie-break contact constants provide good correlation with experimental results and allow for the prediction of the mechanical behavior of intact, damaged, and healed laminated plates. The comparison analysis based on CAI test results and modal characteristics obtained by the 3D Laser Doppler Vibrometer (Polytec GmbH, Karlsbad, Germany) proved that thermal healing partially restores the mechanical properties of damaged laminate plates. In contrast, active thermography does not necessarily indicate a healing effect.

Recipe to Strengthen Continuous Fiber Reinforced 3D Printed Parts

Today, the design of polymer parts by additive manufacturing subjected to large stress has undergone a clear advance with the new concept of continuous fiber-reinforced thermoplastic composites (CFRTPC). The optimization of fiber alignment is the main asset to improve strength and has been widely discussed by the research community. In this work, the effect of the intercalation of the polymeric matrix (ONYX) between layers of continuous fiberglass reinforcement has been analyzed in shear specimens. Onyx is nylon mixed with short carbon fibers. The results show how inserting polymeric layers among the continuous fiber ones improves the shear strength up to 25% and the stiffness modulus up to 18%.

Evolution of Manufacturing Defects of 3D-Printed Thermoplastic Composites with Processing Parameters: A Micro-CT Analysis.

Owing to the melting and healing properties of thermoplastic resin, additive manufacturing or 3D printing is considered one of the most promising technologies for fiber-reinforced thermoplastic composites. However, manufacturing defects are still the main concern, which significantly limits the application of 3D-printed composite structures. To gain an insight into the effects of different processing parameters on the typical manufacturing defects, a micro-scale analysis was carried out via Micro-CT technology on the 3D-printed continuous carbon fiber-reinforced polylactic acid (PLA) composite specimens. The bias distribution of the fiber in the deposited filament was found. Moreover, when the feed rate of the filament was reduced from 100% to 50%, the a/b value was closer to 3.33, but the porosity increased from 7.077% to 25.352%. When the layer thickness was 0.2 mm, the increased nozzle pressure reduced the porosity but also increased the risk of fiber bundle breakage. The research provides an effective approach for analyzing the micro-structure of 3D printed composite structures and thus offers guidance for the processing control.