Thermoplastic Materials Research Articles

An Analytical Friction Model for Handling and Spreading of Carbon Fiber Tows for Composite Prepregging Applications

Abstract A novel co-extrusion system for continuous fiber-reinforced thermoplastic composites in filament and narrow-tape format was designed, fabricated, and tested. The new modified pultrusion process, called In Situ Impregnation, impregnates continuous dry fiber reinforcement tows in situ with thermoplastic matrix for applications ranging from 3D printing using robotic manipulation to automated fiber placement. The technical goal of the system is to directly co-extrude and impregnate a reinforcement fiber tow (carbon) with thermoplastic matrix injected by an extruder fed with thermoplastic pellets. This approach uses inexpensive materials instead of “prepreg” tow in order to streamline the additive manufacturing process, cut costs for advanced composites manufacturing, and deliver fully customizable fiber orientation. The purpose of this paper is to discuss analytical modeling of friction and fiber tensioning in the system which allows for the full impregnation of the fibers. Experiments were conducted on a working pultrusion system where load was adjusted through the tensioning system to better understand the amount of friction throughout the system, the magnitude of tension in the fiber tow, and to validate the models. The resulting friction model can be used by machine designers to estimate the tension in tows, ropes, fibers, etc. in similar tensioning devices, and estimate automated system specifications such as motor requirements. A brief description of the new manufacturing process is also provided. Future work includes commercialization of the technology, automation of the manufacturing system, and further modeling work to predict fiber spreading behavior based on geometric factors.

The Use of Thermal Data for Quality Assurance in the Process of Continuous Ultrasonic Welding of Thermoplastic Composite Materials

Continuous ultrasonic welding (CUW) is a manufacturing process used to join thermoplastic composite materials using high-frequency ultrasonic vibrations. Under pressure and vibration, the welding material heats up, melts and the welding partners are joined while they are cooling down. The development of CUW is getting raised attention over the last decade since the use of thermoplastic composites (TCs) in the production industry and especially the aerospace sector demands for economic and fast joining techniques. In order to establish this welding technique in the industry it is necessary to develop methods which enable to do quality assurance on the produced welding seams. In the experiments described in this paper the potential of thermal measurements for the quality assurance of the ultrasonic welding of TCs is investigated. Different thermal systems are evaluated and it is described how the data of the most promising technique is further processed and fed to an artificial intelligence (AI) algorithm. The here trained networks are created to predict lab-shear-strength values and reach mean absolute error scores of below 1 MPa. The described investigations hint that thermography seem to be a valuable resource to make more reliable quality assurance in the process of CUW of TCs and therefore might help to establish the use of this welding technology further in the industry.

Shape-Memory Polymers Based on Carbon Nanotube Composites.

For the past two decades, researchers have been exploring the potential benefits of combining shape-memory polymers (SMP) with carbon nanotubes (CNT). By incorporating CNT as reinforcement in SMP, they have aimed to enhance the mechanical properties and improve shape fixity. However, the remarkable intrinsic properties of CNT have also opened up new paths for actuation mechanisms, including electro- and photo-thermal responses. This opens up possibilities for developing soft actuators that could lead to technological advancements in areas such as tissue engineering and soft robotics. SMP/CNT composites offer numerous advantages, including fast actuation, remote control, performance in challenging environments, complex shape deformations, and multifunctionality. This review provides an in-depth overview of the research conducted over the past few years on the production of SMP/CNT composites with both thermoset and thermoplastic matrices, with a focus on the unique contributions of CNT to the nanocomposite's response to external stimuli.

Failure analysis of thermoplastic composites subject to galvanic corrosion in hybrid metal–composite joints

The damage sustained by carbon fibre reinforced polymers due to the effect of galvanic corrosion induced by coupling between carbon fibres and a metallic material in a hybrid joint is investigated. Composite laminates with two fibre architectures and two thermoplastic matrices (polycarbonate and polyamide 6) are coupled to a metallic fastener and exposed to salted fog conditions. Both the effects of the salted fog environment and the coupled effect of the environmental and the galvanic corrosion are analysed. The analysis is centred in, firstly, characterising the functional properties of the hybrid joint, secondly characterising the laminate properties and finally characterising the chemical degradation of the matrix. The results show a degradation of properties for the polycarbonate material, in terms of bearing performance and interlaminar shear strength as well as presenting obvious changes in the thermal characterisation. The polyamide composites remain largely unaffected and only minor changes in the surface appearance are noteworthy.

DESIGN A SINGLE SCREW EXTRUDER FOR POLYMER-BASED TISSUE ENGINEERING

In the area of tissue engineering, single screw extrusion (SSE) has gained attention due to its versatility and efficiency in fabricating polymer-based scaffolds. Furthermore, advancements such as the implementation of extrusion techniques and the integration of bioactive agents have significantly expanded the capabilities of SSE. This study aims to investigate the configuration of a custom-designed plastic extrusion for tissue engineering, highlighting its potential in fabricating suture technology for various regenerative biomedical applications. Furthermore, the challenges and future perspectives in SSE technology are discussed, with a focus on the need for additional research to optimize processing parameters, enhance structure bioactivity, and facilitate clinical usage. SSE provides precise regulation of structure morphology, mechanical properties, and porosity, which are critical factors that influence cell behavior and tissue regeneration. Overall, SSE holds great promise as a scalable and cost-effective manufacturing technique for producing polymer-based structures with tailored properties, advancing the field of tissue engineering towards effective clinical solutions. The paper provides a comprehensive overview of a filament extruder production machine that is capable of manufacturing high-quality filament sutures (FS) using thermoplastic materials, specifically bio-protein derived from human serum albumin. The main focus of the paper is to explain the design and operation principles of the filament extruder. The extruder is equipped with a die that can measure a range starting from 2.5 mm and going down to smaller scales. This allows for the extrusion of filaments with a diameter as small as 1.75 mm. Although the design of the extrusion apparatus closely resembles that of commercially available machines, the focus here is on its adaptability and cost-effectiveness for laboratory-scale production. Overall, the research contributes to advancing the understanding of extrusion processing technologies in the context of biomedical applications, with a specific focus on utilizing human serum albumin-derived thermoplastics for manufacturing FS.

Simplified Fabrication of a Lingual Splint for Management of Mandibular Fractures.

Lingual splints have been used to treat mandibular fractures, particularly in cases of complicated mandibular fractures, and serve as a noninvasive adjunctive procedure for reduction and fixation. Furthermore, when used in conjunction with open reduction and internal fixation, the lingual splint provides feasible external fixation against displacing forces exerted by the robust musculature of the mandible. However, the conventional method for lingual splint fabrication is performed preoperatively, and the procedure is time-consuming. This technical note describes a simplified and efficient technique for the intraoperative manufacture of a lingual splint for mandibular fractures using a thermoplastic material, polycaprolactone. Our results demonstrated satisfactory fixation outcomes, reduced lingual splint fabrication time, and superior cost-effectiveness, offering an alternative option for adjunctive external fixation of mandibular fractures.

The thermal 'Buddha Board'-application of microstructured polyolefin films for variable thermal infrared transparency materials.

In this study, we explore the innovative application of biological principles of scattering foams and structural colouration of white materials to manipulate the transmission properties of thermal infrared (IR) radiation, particularly within the 8-14 μm wavelength range in polyolefin materials. Inspired by the complex skin of organisms such as chameleons, which can dynamically change colour through structural alterations, as well as more mundane technologies such as Buddha Boards and magic water colouring books, we are developing methods to control thermal IR transmission using common thermoplastic materials that are semi-transparent to thermal IR radiation. Polyethylene and polypropylene, known for their versatility and cost-effectiveness, can be engineered into microstructured sheets with feature sizes spanning from 5 to 100 μm. By integrating these precisely moulded microstructures with index-matching fluids, specifically IR transparent oils, we achieve a reversible modification of the thermal transmission properties. This novel approach not only mimics the adaptive functionality of natural systems but also offers a practical and scalable solution for dynamic thermal management. Our results indicate a promising pathway for the development of new materials that can adapt their IR properties in real time, paving the way for smarter thermal management solutions via radiative emission/absorption.

Orthotic Thermoplastic Demonstrates a Similar Contamination Potential with Bacillus Bacteria Recovered from Thermoplastic Radiation Therapy Patient Masks

Thermoplastics used to construct a variety of patient medical devices can become contaminated by harmful bacteria. We investigated whether two different Bacillus species recovered from patient radiation therapy thermoplastic masks could similarly contaminate thermoplastic material used to construct patient orthoses (splints). Bacillus bacteria form dormant spores, which have been shown to enhance its attachment to thermoplastics. Bacterial attachment and recovery were examined using an orthotic thermoplastic with an anti-stick coating being compared to uncoated material used in radiation therapy applications. Triplicate sample squares were seeded with a saline suspension of either B. cereus (MAB03F) or B. megaterium (DAB01F) containing a similar number of spores. Squares were subsequently sampled at 1 h, 1 week, 2 weeks, 4 weeks, and 8 weeks. The number of recovered bacteria was counted. Differences in material hydrophobicity were determined by water contact angle analysis. Both Bacillus species attached to each material within 1 h, and their spores were recovered at 8 weeks. However, a decreasing trend in adhesion, over time, was noted to the coated material with an opposite increasing trend in the uncoated material. Decreased Bacillus species spore adhesion to coated material with a lower hydrophobicity suggests a greater potential for spore transfer to patients wearing contaminated orthoses.

Making wind turbine blades more sustainable

Researchers at Virginia Tech’s College of Engineering will use new methods of additive manufacturing, computational design, and a recyclable, high strength thermoplastic material to improve the environmental footprint of wind turbine blade production.

The cytotoxicity assessment of different clear aligner materials

Background/purposeInvisible orthodontic treatments are becoming increasingly popular, and numerous brands of invisible aligners are now available. However, concerns remain about the safety of the materials used in these products. This study aimed to assess the cytotoxic effects of both original and thermoformed thermoplastic materials used in orthodontic aligners on human periodontal ligament (HPDL) cells in vitro. Materials and methodsThe experiment used six different brands, each containing three types of thermoplastic materials, Polyethylene terephthalateco-1, 4-cyclohexylenedimethylene terephthalate (PETG), thermoplastic polyurethane (TPU), and copolyester polyethylene terephthalate (PET). The original sheets and the thermoformed materials were soaked in a culture medium for seven and fourteen days, and then applied to cultured human periodontal ligament cells. Cells were harvested on the first, third, and fifth days after application, and their viability was analyzed using the MTT [3-(4,5-dimethylthiazol-2-yl)-2,5-diphenyl tetrazolium bromide] assay. ResultsThe findings revealed that some thermoformed materials, notably PETG, exhibited lower survival rates compared to their non-thermoformed versions. However, other materials such as TP and PET maintained over 70% cell viability, indicating only minor cytotoxic effects. ConclusionThese findings highlight the need for further research into the long-term biocompatibility of these materials but generally affirm their safety for use in orthodontic aligners under the tested conditions.

Research Progress of 3D-Printed Polyetheretherketone in Implantable Medical Devices

Polyetheretherketone (PEEK) has emerged as a thermoplastic material of choice in the realm of implantable medical devices, owing to its high biocompatibility and exceptional mechanical strength. Despite its promise for custom-made medical devices, 3D-printed PEEK in orthopedics, trauma, and spinal implants has not yet achieved widespread application. This study outlines the properties of PEEK, 3D-printed PEEK-based composites, and their utilization in implantable medical devices, thereby fostering the development and regulation of next-generation medical devices.

A new effective phenomenological constitutive model for semi‐crystalline and amorphous polymers

AbstractA new phenomenological constitutive model is proposed for the prediction of the tensile and compressive behavior of semi‐crystalline and amorphous polymers. The new model modifies the phenomenological model previously proposed by Zhou and Mallick (ZM model) to correctly predict the complex behavior of thermoplastic materials including the linear viscoelastic deformation, the non‐linear viscoelastic deformation, the yielding, the post‐yield strain softening and the post‐yield strain hardening. A validation activity based on literature data has been carried out for polyether‐ether‐ketone (PEEK) and polycarbonate (PC) materials. The new model proved effective in fitting with high accuracy all the phases of the flow stress behavior for the considered materials, across a wide range of strain rates and temperature conditions. Finally, the comparison with Zhu et al., Duan et al., Nasraoui et al., Mulliken‐Boyce and Zhou‐Mallick models showed the better fitting performance of the proposed phenomenological model.Highlights Formulation of a new phenomenological model. Validation on mechanical test of semi‐crystalline and amorphous thermoplastics. Comparison with different phenomenological models present in the literature. Superior prediction results achieved compared to previously developed models.

Research on the thermal conductivity and mechanical properties of carbon fiber reinforced thermoplastic composites doped with different sizes carbon nanotubes: A combination of experiments, numerical simulations and multi‐objective optimization

AbstractWhile improving the thermal conductivity of composites, single‐size carbon nanotubes (CNT) often degrade their mechanical properties due to the agglomerates. To overcome this limitation, this study reported thermoplastic resin matrix composites synergistically reinforced with small, medium, and large‐size carbon nanotubes (S‐CNT, M‐CNT, and L‐CNT). Using the thermal conductivity (λ) and mechanical properties (flexural strength [F], compressive strength [C] and tensile strength [T]) as the response values, we conducted 21 sets of mixing design experiments and developed the associated quadratic term models. Further multi‐objective optimization was carried out for the above response values. Optimized multiscale CNT synergistically modified composites (S‐CNT, M‐CNT, and L‐CNT contents of 1.25, 7.02, and 2.56 wt%) exhibited a λ value of 1.168 W/mK, which was 121% higher than that of pure composite and also superior to the same content of S‐CNT‐ (1.031 W/mK), M‐CNT‐ (1.016 W/mK), and L‐CNT‐modified composites (0.983 W/mK). Additionally, the optimized composite demonstrated excellent mechanical properties (F = 1482 MPa, C = 848 MPa, and T = 1759 MPa), which were 13%, 11%, and 13% higher than those of the pure composites, respectively, and also surpassed those of the S‐CNT‐, M‐CNT‐and L‐CNT‐modified composites.Highlights Using three different scales of carbon nanotubes modified CF/PPBESK composites. Polynomial modeling of composite's thermal conductivity and mechanical properties. Synergistic interactions between carbon nanotubes to improve the composite's thermal conductivity and mechanical properties.

An experimental‐based thermal prediction model for butt fusion welding of polymer pipes

AbstractHigh‐density polyethylene (HDPE) is one of the most used thermoplastic materials for piping applications, due to its significant advantages. The butt‐fusion process is the most used joining processes for HDPE welding. During the process, the behavior of the material changes. This behavioral change depends on the applied welding process and on the used parameters. Thermal analysis can be used as a tool to reveal and evaluate the modifications of the physical and mechanical properties. In this study, an experimental program was applied to HDPE to assess the effects of different parameters on the welding process including heating temperature, heating duration and the applied strength. Tests are performed according to a full factorial design of experiment (DOE). Mathematical models derived from experimental data are used to establish relationships between the input parameters, such as force and heating duration and the corresponding outputs such as temperature distribution during the different welding phases and the thickness of the molten polymer. The empirical models can be used to implement a control strategy for the temperature and hence quantify the thickness of the molten zone to improve the quality of the weld joint by selecting the appropriate welding conditions for the molten zone.Highlights High‐density polyethylene piping butt‐fusion joint examination using Infrared imaging. Spatial–temporal distribution of temperature for different phases of the welding process. Mathematical Regression techniques are performed. Thickness of molten polymer is assessed. Results are useful for saving material and improvement of the process.

3D composite printing: study of carbon fiber incorporation to different construction thermoplastic matrices in regard to dilatation characteristics

PurposeThe purpose of this paper is to clarify the relationship between the use of different polymer matrices for the preparation of composite materials, namely, polyethylene terephthalate-glycol (PET-G) and polyamide (PA), using Composite Fiber Co-Extrusion technology with the application of two types of carbon fibers, short and continuous. The aim of the study is also to extend the knowledge of the production of composite materials with a defined structure from the point of view of their influence on the microstructure and their physical-mechanical properties.Design/methodology/approachAs part of the experiment, four types of samples were prepared, namely, two types of samples with PA polymer matrix and two types with PET-G polymer matrix. All types contained short carbon fibers and always one set from each polymer matrix in addition to continuous carbon fibers. All types were prepared using the same 3D printing parameters to avoid any further influence. The samples were then tested for microstructure using microCT, mechanical properties using a tensile test and dilatation characteristics from the point of view of aerospace applications. Finally, the raw materials themselves were tested.FindingsThe paper provides insight into the influence of polymer matrix types on the physico-mechanical properties of 3D printed composites. The analysis confirmed that the physico-mechanical results varied with respect to the interface between the polymer matrix and the carbon fiber. The implications of the conclusions can be extended to the development of products in the aerospace and automotive sectors.Originality/valueThis study provides information for composite applications in the aerospace industry, focusing on evaluating dilatation characteristics within very low temperatures (−60 °C) when using carbon fibers (continuous carbon fibers, short carbon fibers and a combination of both) in two types of thermoplastic matrices. This perspective on materials characterisation for aerospace applications is a very important and unpublished approach within the 3D printing of composites. These characteristics are important parameters in the design of prototypes and functional samples with regard to the resulting behaviour in real conditions.

Patterning of COC Polymers by Middle‐Energy Ion Beams for Selective Cell Adhesion in Microfluidic Devices

AbstractMicrofluidic devices play a crucial role in advanced cell biology applications, including cell separations, cultivations, migration and interaction studies, diagnostic devices, and organ‐on‐chips. One of the frequent purposes of such devices is the ability to selectively address the attachment of cells at defined locations on the surface. This study explores the application of middle‐energy carbon, oxygen, and nitrogen ions to locally modify the surface of cyclic olefin copolymer (COC) thermoplastic material, allowing selective cell growth on patterned polymer surfaces. The investigation considers ion element type, ion beam energy, and ion irradiation fluence, analyzing their influence on the modification effect. Characterization of the modified surfaces involves various surface‐analytical methods such as contact angle, energy dispersive spectroscopy (SEM‐EDX), atomic force microscopy (AFM), x‐ray photoelectron spectroscopy (XPS), rutherford backscattering spectrometry (RBS), and elastic recoil detection analysis (ERDA). The study extends to practical aspects, with a representative cancer cell line, MCF‐7, grown on the patterned surface to evaluate the degree of selective attachment. Additionally, the stability of the irradiated patterns is tested under elevated temperatures beyond the glass transition temperature (Tg), demonstrating the compatibility of the approach with hot embossing technology. The findings underscore the potential of ion beam treatment for COC in cell‐biology‐related applications, offering insights into surface modification techniques for enhanced functionality in microfluidic devices.

Experimental study of the importance of fiber breakage on the strength of thermoplastic matrix composites subjected to compression after impact

Post-impact strength and damage tolerance of composite structures stands as a paramount design consideration in the aeronautical industry. In the event of a low velocity impact, a set of damage manifestations within laminated structures are induced, including matrix cracking, delamination and fiber breakage. Despite the critical importance of discerning the influence of each damage type on post-impact compression strength, only a limited number of studies have endeavored to quantify these effects comprehensively. In response to this research gap, we have developed a novel methodology capable of mimicking damage extension and shape caused by a low-velocity impact, while preserving fiber integrity. This innovation is achieved through the application of induced electrical currents, thereby facilitating controlled damage simulation without compromising fiber structural integrity. Our investigation compares the residual stiffness and strength of AS4/PEEK laminates subjected to low velocity impacts and induction currents, under conditions of equivalent damage. Our findings reveal that fiber breakage significantly influences the loss of stiffness in the laminate, but not its strength. Moreover, our results confirm the role of delamination as the primary determinant of strength degradation in the damaged material.

Tribological evaluation of thermoplastic polyurethane-based bearing materials under water lubrication: Effect of load, sliding speed, and temperature

Polymers are widely used in bearing applications. In the case of water-lubricated stern tube bearings, thermoplastic polyurethane (TPU)-based composites are used due to their excellent wear resistance, corrosion resistance, and tunable mechanical properties. Their tribological performance, however, depends on operating conditions. In this work, TPU was blended with carbon fiber, graphene platelet, and ultra-high molecular weight polyethylene (UHMWPE). Friction tests of TPU based-composites against copper countersurface were carried out in water to mimic the actual operating conditions of the bearing. Most of the resulting contacts were in the boundary lubrication regime, in which friction was attributed to both contact mechanics of asperities as well as water lubrication. Our results show that the viscoelasticity of TPU has a considerable impact on its tribological performance. Water lubrication at 50 °C promotes the softening of polymer surface material during sliding, resulting in higher fluctuation in the coefficient of friction and wear loss. This is attributed to the reduced thermomechanical properties. In addition, Schallamach waviness is observed on worn surface. The tribological properties of TPU are significantly improved by the inclusion of carbon fiber, graphene platelet, and UHMWPE. The formation of graphene transfer-layers and UHMWPE transfer film reduces friction and wear loss, while the inclusion of carbon fiber enhances wear resistance due to improved mechanical properties and load bearing capacity.

Optimization, Design, and Manufacturing of New Steel-FRP Automotive Fuel Cell Medium Pressure Plate Using Compression Molding

In this work, a new plastic-intensive medium-pressure plate (MPP), which is part of a fuel-cell system, has been developed together with a steel plate meeting all mechanical and chemical requirements. This newly developed MPP had to achieve the objective of saving weight and package space. The use of compression molding as a manufacturing technique facilitated the use of glass mat thermoplastics (GMT) which has higher E-modules and strength compared to most of the injection molded materials. A steel plate was placed as an insert to help achieve the stiffness requirements. For the development, the existing MPP was benchmarked for its structural capabilities and its underlying functional features. Four different FRP materials were investigated in terms of their chemical and mechanical properties. PP-GMT material, which has both high mechanical performance and resistance against chemicals in the fuel cell fluid, had been chosen. Using the properties of the chosen PP-GMT material, topology optimization was carried out based on the quasi-static load case and manufacturing constraints, which gave a load-conforming rib structure. The obtained rib structure was utilized to develop the final MPP with adherence to the functional requirements of MPP. The developed plastic-intensive MPP exhibits a 3-in-1 component feature with a 55% reduction in package space and an 8% weight reduction. The MPP was virtually analyzed for its mechanical strength and compared with the existing benchmark values. Finally, a press tool was conceptualized and manufactured to fabricate the new plastic-intensive MPP, which was tested in a rig and validated in the FE model.

Comparative study of iontophoresis-assisted transdermal delivery of bupivacaine and lidocaine as anesthetic drugs.

Postoperative pain management is an important aspect of the overall surgical care process. Effective pain management not only provides patient comfort but also promotes faster recovery and reduces the risk of complications. Bupivacaine (BUP) and Lidocaine (LID) transdermal drug deliveries via thermoplastic polyurethane matrix (TPU) and iontophoresis technique are proposed here as alternative routes for postoperative pain instead of the injection route. Under applied electric field, the amounts of BUP and LID released were 95% and 97% from the loaded amounts, which were higher than the passive patch of 40%. The time to equilibrium of BUP turned out to be faster than the time to equilibrium of LID by approximately 1.5 times. This was due to 2 factors namely the drug molecular weight and the drug pKa value; they play an important role in the selection of a suitable drug for fast-acting or long-acting for the postoperative patients. By using this transdermal patch via iontophoresis system, BUP was deemed as the suitable drug for fast-acting due to the shorter time to equilibrium, whereas LID was the suitable drug for long-acting. The in-vitro drug release - permeation study through a porcine skin indicated the efficiency and potential of the system with the amounts of drug permeated up to 76% for BUP and 81% for LID. The TPU transdermal system was demonstrated here as potential to deliver BUP and LID for postoperative patients.