连续玻璃纤维/聚丙烯热塑性复合材料拉挤成型中的工艺参数

采用复合纱拉挤方法制备连续玻璃纤维/聚丙烯(GF/PP)热塑性复合材料,研究了复合纱拉挤成型过程中模具温度及拉挤速度对GF/PP复合材料截面中心温度的影响。以傅里叶定律为理论基础,分析了拉挤过程中模腔内的瞬态传热过程;建立了工艺参数矩阵,通过有限元数值计算,预测了不同模具温度、拉挤速度下GF/PP复合材料截面中心的温度变化,优选了工艺参数组合。通过实验制备不同温度、不同拉挤速度的GF/PP复合材料,并进行弯曲模量测试及截面形貌观察。结果表明:在GF/PP复合纱拉挤过程中,拉挤速度不宜超过350 mm/min,模具熔融区温度设定应高于180℃;GF/PP复合材料在150℃-230℃-50℃成型温度、100 mm/min拉挤速度的工艺参数设定下获得最优的制品力学性能;在设定拉挤参数时,拉挤速度相较于熔融区温度更重要。      

热塑性树脂连续浸渍过程的纤维断裂机制及实验

利用自行设计的浸渍模具,通过拉挤熔融浸渍工艺,定量考察了牵引速度、熔体温度和浸渍辊个数等工艺参数对连续玻璃纤维增强热塑性复合材料复合过程中纤维断裂的影响,旨在通过所建立的纤维断裂数学模型,预测预浸料生产过程中纤维断裂率并描述实验结果。结果表明:模型与实验数据吻合较好,能够为工业化生产提供指导与借鉴;纤维束在模具中拖曳而产生的黏性剪切作用是影响纤维断裂的主要因素,适当减少浸渍辊数及采用低黏度树脂能够显著降低纤维断裂,提高工艺稳定性。     

紧张热定型工艺对多壁碳纳米管/聚醚醚酮复合纤维结构和性能的影响

采用熔融共混纺丝工艺制备多壁碳纳米管(MWCNTs)质量分数分别为0.1%和0.5%的MWCNTs/PEEK(聚醚醚酮)复合纤维,研究了紧张热定型过程中热定型温度和降温速率对复合纤维结构和性能的影响。采用TEM、SEM、DSC、DMA、XRD和单纤维电子强力仪研究了复合纤维的形貌、结构和性能。结果表明:复合纤维的热定型温度和冷却降温速率对其杨氏模量、拉伸强度和断裂伸长率均有影响,经过热定型处理,复合纤维内部MWCNTs的取向程度明显提高。280℃热定型、1.5℃/min冷却纤维的拉伸强度达384MPa,杨氏模量为0.62GPa,断裂伸长率28%,拉伸强度和杨氏模量分别较130℃热定型纤维提高了147%和19%,获得了优化复合纤维性能的最佳工艺条件。      

v/p转压方式对注塑制品质量重复精度的影响

对注射成型中四种不同的v/p(射速/压力)转压方式的工艺性能进行了研究,以制品质量作为验证参数,同时考虑了模具温度的变化.研究发现,注塑制品质量重复精度的提高除了受到转压方式的影响还同相应转压方式下的工艺参数设定有关;制品质量的变化受模具温度的影响,常规转压方式下,制品质量随模具温度升高而降低,而模腔熔体温度转压方式下...     

微注塑薄壁制品可成型性及充填过程中的流动现象分析

基于一组薄壁微制品的微注塑成型实验,研究不同尺度(100μm、200μm、500μm、1mm)制品的可成型性及充填过程中的流动现象,获得注塑速度、模具温度和熔体温度对不同厚度制品充填性能的影响,并对成型过程中出现的流动不平衡现象及前沿面形状变化的机理进行了分析。结果表明,型腔充填率随着注塑速度、模具温度、熔体温度的升高而增大,且随着型腔厚度减小,制品实现完整充填越来越困难,工艺操作窗口变窄且注塑速度和模具温度都维持在高水平状态。     

微结构塑件的注塑充填尺度效应

微尺度聚合物熔体流动具有明显的尺度效应,模具温度和注射速率是微注塑充填流动的关键影响因素。文中采用微细电火花铣削技术设计分别制造了一模八腔的带有200μm和300μm微孔的注塑模具。以聚丙烯(PP)进行单因素充模流动工艺实验,研究了模具温度和注射速率对直径为200μm和300μm微圆柱充填高度影响规律。结果表明,当模具温度为30℃和注射速率为60%时,直径200μm微圆柱孔的充填高度小于直径300μm微圆柱孔的充填高度,且Ⅰ型腔的微圆柱充填高度大于Ⅱ的充填高度。随着模具温度升高和注射速率增加,2种微孔充填高度差在减小,Ⅰ型腔和Ⅱ型腔之间的充填高度差值也在减小。可见,升高模具温度和增加注射速率可以减少微尺度效应对微圆柱孔充填高度的影响,同时,还可以减小流动不平衡程度。     

Effects of tension heat-set process on structures and properties of MWCN~/PEEK composite fibers

采用熔融共混纺丝工艺制备多壁碳纳米管（MWCNTs）质量分数分别为0．1％和0．5％的MWCNTs／PEEK（聚醚醚酮）复合纤维,研究了紧张热定型过程中热定型温度和降温速率对复合纤维结构和性能的影响。采用TEM、SEM、DSC、DMA、XRD和单纤维电子强力仪研究了复合纤维的形貌、结构和性能。结果表明：复合纤维的热定型温度和冷却降温速率对其杨氏模量、拉伸强度和断裂伸长率均有影响,经过热定型处理,复合纤维内部MWCNTs的取向程度明显提高。280℃热定型、1．5℃／min冷却纤维的拉伸强度达384MPa,杨氏模量为0．62GPa,断裂伸长率28％,拉伸强度和杨氏模量分别较130℃热定型纤维提高了147％和19％,获得了优化复合纤维性能的最佳工艺条件。     

注射速率对注射制品精度的影响

通过点烧口和直浇口模具，采用PA6、PA1010和HDPE探讨了注射速率对注射制品精度的影响，研究发现，注射速率对精度的影响具有最佳值，即当注射速率低于某一值时，精度随注射速率的增加而提高，而当注射速率高于该值时，精度则随注射速率的增加而下降。初步分析了其产生的原因是注射速率的多种作用造成的，其主要影响因素为型腔尺寸、熔体粘度和浇口类型。     

基于神经网络遗传算法的GFRP拉挤双目标优化

为研究玻璃钢(GFRP)拉挤工艺参数对复合材料性能的影响,优化最佳拉挤工艺参数,建立了拉挤工艺过程数学模型,结合基于有限元/有限差分的间接解耦法进行求解,模拟得到了拉挤过程中GFRP内部的非稳态温度场和固化度变化情况.分别采用布拉格光栅光纤温度传感器和索氏萃取法检测拉挤GFRP内部的温度与固化度,实测温度和固化度均与模拟温度和固化度吻合,验证了数值模拟程序的正确性.以数值模拟结果为样本,建立反向传播神经网络,得到拉挤工艺参数(固化温度、拉挤速度)与GFRP固化度之间的非线性相关关系,再结合遗传算法解决拉挤过程中固化炉温度和拉挤速度双目标优化问题.优化得到的拉挤工艺参数可在保证复合材料固化度达标的情况下,提高拉挤速度降低固化炉温度,优化效果显著.神经网络遗传算法优化方法能有效解决此类具有复杂非线性关系的多目标优化问题.     

海藻/磷虾蛋白复合纤维结构与染色性能研究

采用湿法纺丝技术成功制备了海藻/磷虾蛋白复合纤维(SA/AKP),用含有戊二醛的复合阻溶胀剂与酸性染料配伍使用对复合纤维进行染色,研究了上染率、色牢度、表观色深与染色工艺的关系以及染色前后复合纤维力学性能的变化,并通过FT-IR、SEM对复合纤维的结构进行了分析与表征。结果表明,纤维表面具有沿轴向均匀分布的沟槽结构,截面呈椭圆形,酸性染料对SA/AKP复合纤维具有较好的染色效果,上染率达95.71%;耐水洗牢度达3级以上,K/S值随温度的升高而增大,60℃之后K/S值随温度的升高增加较为缓慢,染色后纤维的力学性能损失率随染色温度的升高而减小,80℃染色时纤维力学性能提高了0.3%,初始模量略有降低为3.7%。     

Mechanical properties of biaxial weft-knitted flax composites

There has been an increasing interest of using natural fibers to replace glass fibers for composite reinforcement nowadays. However, most of the developments have focused on the random discontinuous fiber composite system. In this study, low cost flax continuous yarn was used to make non-crimp fabric for composite reinforcement based on a biaxial weft-knitted structure. A modified flat knitting machine was developed to produce this kind of reinforcement. Both NaOH treated and untreated reinforcements were used for fabricating the composite samples through the vacuum assisted resin transfer molding process (VARTM). The mechanical properties of the flax yarn, reinforcement and composites were tested and the effect of the NaOH treatment was discussed. The results revealed that although the NaOH treatment resulted in the reduction of the mechanical properties of both yarn and reinforcement, the mechanical properties of the composites could be considerably improved by the NaOH treatment of the reinforcement. The study has provided a simpler way of using low cost natural fiber yarns made from flax long-fiber bundles to produce high performance composites.     

Pultrusion of a flax/polypropylene yarn

The present work reports the pultrusion of a flax reinforced polypropylene commingled yarn containing discontinuous flax and polypropylene fibers. This was the first attempt to pultrude this material. Rectangular cross-sectional profiles have been successfully produced using a self-designed pultrusion line. In a series of experiments carried out with yarns of two different flax fiber contents, the pultrusion parameters were varied. In particular, the preheating and die temperatures and also the pulling speed, which are the most relevant parameters regarding the potential future pultrusion of natural fiber composite profiles at industrial scale. A complete characterization of each profile was conducted in order to examine the influence of processing parameters on the profile quality. The mechanical properties were evaluated by performing three point bending as well as Charpy impact tests.     

纬编双轴向织物/环氧树脂电加热复合材料电热及层间剪切性能

为开发一种可用于航空飞行器防/除冰防护的电加热复合材料,本文设计制备了三种纬编双轴向织物/环氧树脂复合材料,采用实验方法研究了纬编双轴向织物电阻丝排列密度对复合材料电热性能和层间剪切性能的影响。电加热复合材料上、下层均为玻璃纤维/环氧树脂预浸料,中间层为电加热纬编双轴向织物,织物衬经纱、捆绑纱和衬纬纱分别采用铜镍合金丝、涤纶和玻璃纤维。采用红外温度测试仪和材料万能试验机进行性能测试。结果表明:施加电压6 s后复合材料表面温度快速升高,在60 s左右温度达到最高平衡温度,复合材料表面最高平衡温度与施加电压成正比关系;当施加电压不变时,电阻丝排列密度越小,复合材料表面最高平衡温度越高;电阻丝排列密度越小,复合材料层间剪切强度越大。可见,纬编双轴向织物/环氧树脂电加热复合材料具有轻质高强、加热速率高、成型性好等特点,适合用于飞行器多个部位的防/除冰。      

新型轻木GFRP夹芯板拉挤成型工艺及其界面性能

选用无碱玻璃纤维束、短切纤维毡、不饱和树脂与泡桐木芯材,制备了轻木-玻璃纤维增强塑料(GFRP)夹芯板,对其拉挤工艺进行了研究.研究表明:设定模具加热温度(凝胶区)为160 ℃、选取的拉挤速率为10 cm/min时,可制造得到表观性能良好的泡桐木-GFRP夹芯板.通过双悬臂梁(DCB)试验,在芯材表面开槽和不开槽2种情况下,研究了泡桐木与GFRP面层之间的界面黏结性能,并与真空导入工艺制作的夹芯板的界面黏结性能进行了对比.结果表明:拉挤工艺生产的泡桐木-GFRP夹芯板的界面黏结性能已达到甚至优于真空导入工艺生产的.芯材表面开槽可以有效提高试件的界面能量释放率,且对真空导入工艺制作的试件效果更为明显.在拉挤工艺中,树脂难以有效填充齿槽形成"树脂钉",故不能明显提高界面黏结力.在对界面性能要求不严格时,拉挤工艺中芯材表面可不开槽,以减少生产工序、降低生产难度.     

有机复合绝缘子用耐酸性拉挤电绝缘芯棒

采用丙烯酸改性酚醛环氧树脂,并对以此树脂为基体,以DDSA为增韧剂研制成功一种耐酸性玻璃钢拉挤电绝缘芯棒用树脂基体配方。应用DSC、TGA和FT-IR等分析技术对该改性树脂基体的固化反应进行了研究,对其浇铸体以及玻璃纤维增强的拉挤芯棒的耐酸性、耐热性等性能也进行了研究。结果表明:该树脂基体满足拉挤工艺要求,用此树脂基体制得的玻璃钢拉挤芯棒具有优异的耐酸性以及良好的机电热性能。     

On the recyclability of a cyclic thermoplastic composite material

The recyclability of a novel cyclic thermoplastic composite material has been investigated. The virgin composite was prepared by liquid molding the cyclic thermoplastic resin and a knitted glass fabric. The resultant high fiber content composite (58.7% fiber weight fraction) was recycled by grinding/compounding/injection molding process. A variety of physical and mechanical tests were then conducted on the blended cyclic composite and a baseline, commercially available short fiber reinforced thermoplastic composite. In general, the recycled cyclic composite demonstrated comparable properties to the baseline material. The only exception being the ultimate tensile elongation of the recyclate, which was almost 25% lower than that of the baseline.     

玻璃纤维膨体纱保温材料的开发及性能探讨

首先,选用玻璃纤维无捻粗纱制备了玻璃纤维膨体纱、玻璃纤维膨体花式纱及玻璃纤维膨体纱织物。其次,研究了玻璃纤维无捻粗纱和膨体纱的化学结构,并观察了它们的形态结构。最后探讨了膨体纱织物的透气性、力学性能、固定树脂能力及热防护性能。结果表明:玻璃纤维膨体纱织物外观丰厚,且存在较多空隙,具备良好的蓬松性、透气性、固定树脂能力及热防护性能。     

Design and manufacturing of an L-shaped thermoplastic composite beam by braid-trusion

Braid-trusion is a manufacturing process for composite materials in which a braiding machine is coupled with a pultrusion die to continuously produce beams with constant cross-section and off-axis fiber orientation. This study presents a geometrical model of the tri-axial braid which allows the design of braided preforms that achieve correct filling of the pultrusion die at the same time as it limits fiber friction on die walls. The typic design parameters are listed and used for the manufacturing of a braid-truded thermoplastic composite beam where fibers are aligned at ±69° as well as 0° with respect to the beam axis. Tensile mechanical characterization and cross-section observations are also presented.     

Investigation of the pressure behavior in a pultrusion die for graphite/epoxy composites

There are a variety of ways to process composite materials. One such way is pultrusion which is a continuous process for manufacturing composite materials of constant cross-sections. The pultrusion process involves a number of variables and processing parameters which can affect the quality of a pultruded product. One variable of particular interest is the fluid resin pressure rise in the tapered inlet region of the die. The liquid resin pressure rise in the die inlet can have a significant impact on the quality of a pultruded product. An appreciable pressure rise can suppress void formations and enhance fiber “wet out”. Darcy’s law for flow in a porous media is used to mathematically model the fiber/resin system of the pultrusion process, while employing the finite volume solution method to predict the pressure and velocity fields as a function of various process control parameters. The results obtained by the numerical model can establish a foundation by which process control parameters are selected to achieve an appreciable pressure rise which will enhance the quality of the pultruded composite. The results can also be applied to die inlet design.