Visual analysis of plastication of long‐glass fiber‐reinforced resins using a glass‐insert heating cylinder

The fiber‐reinforced plastication processes during the injection molding of reinforced resins with long fibers are difficult to observe through visualization cylinders because of possible obstacles, such as (1) opacification of melts, (2) abrasion on the inner surface of glass windows, and (3) breakage of glass windows under high pressures. In this study, we visualized the plastication process of long‐glass fiber‐reinforced resins containing 50 wt% fibers. In plastication experiments using three full‐flight screws with different compression ratios, we observed the instability of the melting process, the generation of solid beds and melt pools, and the breakup of melted segments. We demonstrated that the plastication process depends considerably on the compression ratio and clarified the characteristic molding phenomena related to fiber breakup. Based on our observations, we proposed a model that explains the different fiber breakage distributions at different compression ratios during the melting process of long‐glass fiber‐reinforced resins. POLYM. ENG. SCI., 59:1300–1309 2019. © 2019 Society of Plastics Engineers     

Properties enhancement of short glass fiber‐reinforced thermoplastics via sandwich injection molding

This article demonstrates using sandwich injection molding in order to improve the mechanical properties of short glass fiber‐reinforced thermoplastic parts by investigating the effect of fiber orientation, phase separation, and fiber attrition compared to conventional injection molding. In the present case, the effect of short glass fiber content (varying from 0–40 wt%) within the skin and core materials were studied. The results show that the mechanical properties strongly depend not only on the fiber concentration, but also on the fiber orientation and the fiber length distribution inside the injection‐molded part. Slight discrepancies in the findings can be assumed to be due to fiber breakage occurring during the mode of processing. POLYM. COMPOS., 26:823–831, 2005. © 2005 Society of Plastics Engineers     

Properties of glass‐filled thermoplastic polyesters

The thermal, mechanical, and rheological properties of glass‐filled poly(propylene terephthalate) (GF PPT) were compared to glass‐filled poly(butylene terephthalate) (GF PBT). The impetus for this study was the recent commercial interest in PPT as a new glass‐reinforced thermoplastic for injection‐molding applications. This article represents the first systematic comparison of the properties of GF PPT and GF PBT in which differences in properties can be attributed solely to differences in the polyester matrices, that is, glass‐fiber size and composition, polymer melt viscosity, nucleant content and composition, polymerization catalyst composition and content, and processing conditions were kept constant. Under these controlled conditions, GF PPT showed marginally higher tensile and flexural properties and significantly lower impact strength compared to GF PBT. The crystallization behavior observed by cooling from the melt at a constant rate showed that GF PBT crystallized significantly faster than did GF PPT. Nucleation of GF PPT with either talc or sodium stearate increased the rate of crystallization, but not to the level of GF PBT. The slower crystallization rate of GF PPT was found to strongly affect thermomechanical properties of injection‐molded specimens. For example, increasing the polymer molecular weight and decreasing the mold temperature significantly increased the modulus drop associated with the glass transition. In contrast, the modulus–temperature response of GF PBT was just marginally influenced by the polymer molecular weight and was essentially independent of the mold temperature. © 1999 John Wiley & Sons, Inc. J Appl Polym Sci 74: 889–899, 1999     

In situ polymerization and nano‐templating phenomenon in nylon fiber/PMMA composite laminates

Supercritical Carbon Dioxide (SC CO₂) is used as a reaction/processing medium in the fabrication of fiber‐reinforced composite materials. SC CO₂ allows resin (reactive monomer), to penetrate inside the fibers themselves, partitioning into the amorphous regions of the fiber. The crystal structure then templates polymerization of matrix within the fiber. This process produces a composite that exhibits ultralong‐range order from the nanoscale reinforcement of crystals to the macroscale fiber reinforcement of matrix. In addition, SC CO₂ lowers resin viscosity and aids in wetting out Nylon 6,6 fiber reinforcement in a process similar to reaction injection molding (RIM) or resin transfer molding (RTM). This article will discuss the fabrication technique in detail, including process parameters and the structure of resulting composites and morphology of modified fibers. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 88: 1600–1607, 2003     

Manufacturing and testing of long basalt fiber reinforced thermoplastic matrix composites

In this work, long basalt fiber reinforced composites were investigated and compared with short basalt fiber reinforced compounds. The results show that long fiber reinforced thermoplastic composites are particularly advantageous in the respects of dynamic mechanical properties and injection molding shrinkage. The fiber orientation in long basalt fiber reinforced products fundamentally differs from short basalt fiber reinforced ones. This results in more isotropic molding shrinkage in case of long basalt fiber reinforced composites. The main advantage of the used long fiber thermoplastic technology is that the special long fiber reinforced pellet can be processed by most conventional injection molding machines. During extrusion compounding the fibers in the compound containing 30 wt% fibers are fragmented to an average length of 0.48 mm (typical of short fiber reinforced thermoplastic compounds), this length decreases further during injection molding to 0.20 mm. Contrarily using long fiber reinforced pellets and cautious injection molding parameters, an average fiber length of 1.8 mm can be achieved with a conventional injection molding machine, which increased the average length/diameter ratio from 14 to 130. POLYM. ENG. SCI., 2010. © 2010 Society of Plastics Engineers     

Graphene coating assisted injection molding of ultra‐thin thermoplastics

High strength light weight parts are critical for the development of new technologies, particularly electronic devices, such as laptop computers, smart phones, and tablet devices. Injection molded plastics and composites are excellent choices for mass producing such parts. As the part thickness decreases from traditional injection molding (>2 mm thickness) to thin wall molding (～1 mm thickness), and lastly, to ultra‐thin wall molding (<0.5 mm thickness), avoiding incomplete filling (short shots) becomes more challenging. Even though, methods exist today for molding thin‐wall plastic parts (i.e., fast heating/fast cooling injection molding), they require multiple steps resulting in a noncost efficient process. In this article, we demonstrate the technical feasibility of using graphene coating to facilitate flow, by promoting slip at the mold walls. We evaluate the influence of coated and uncoated mold inserts on fiber orientation. We present experimental results using un‐reinforced polypropylene and a 40% by weight carbon fiber reinforced polycarbonate/acrylonitrile butadiene styrene. POLYM. ENG. SCI., 55:1374–1381, 2015. © 2015 Society of Plastics Engineers     

Enhanced β‐crystal formation of isotactic polypropylene under the combined effects of acid‐corroded glass fiber and preshear

The acid‐corroded glass fiber (GF)/isotactic polypropylene (iPP) composite was injection molded by mixing–injection molding (MIM). Through this method, preshear can be imposed on melt during mix–plasticization process. The crystalline structure across the thickness direction of the injection‐molded bars was investigated by wide‐angle X‐ray diffraction and differential scanning calorimetry (DSC). It was unexpectedly found that, in core region, the acid‐corroded GF/iPP sample has the highest content of β‐form crystals, followed by uncorroded GF/iPP and neat iPP. Additionally, the crystalline morphology was investigated by polarized optical microscopy (POM) and scanning electron microscopy, and the results showed that β‐transcrystallization is preferably present in the acid‐corroded GF/iPP system. Confirmed by POM and DSC, the acid‐corroded GF shows strong β‐nucleation ability to iPP under static condition. Combined with the main features of MIM, three β‐nucleation origins in the acid‐corroded GF/iPP system under injection molding condition are proposed: (1) precursors induced by preshear in the barrel, (2) row‐nuclei induced by local shear, and (3) the acid‐corroded GF nuclei. POLYM. COMPOS. 34:1250–1260, 2013. © 2013 Society of Plastics Engineers     

Studies on mechanical properties of sisal fiber/phenol formaldehyde resin in‐situ composites

Phenol formaldehyde resin (PF) reinforced with short sisal fibers (SF) were obtained by two methods, direct‐mixing and polymerization filling. Impact and bending properties of resulting composites were compared. Under the same compression molding conditions, polymerization filled composites showed better mechanical properties than those of direct‐mixed composites. The influences of fiber modifications on the mechanical properties of SF/PF in‐situ (polymerization filled) composites have been investigated. Treated‐SF‐reinforced composites have better mechanical properties than those of untreated‐SF‐reinforced composites. The effects of SF on water absorption tendencies of SF/PF composites have also been studied. In addition, sisal/glass (SF/GF) hybrid PF composites of alkali‐treated SF were prepared. Scanning electron microscopic studies were carried out to study the fiber‐matrix adhesion. POLYM. COMPOS., 2009. © 2008 Society of Plastics Engineers     

Injection molding of long sisal fiber–reinforced polypropylene: Effects of compatibilizer concentration and viscosity on fiber adhesion and thermal degradation

A two‐step process was used to obtain long sisal fiber‐polypropylene (SF/PP)–reinforced thermoplastic composites, using maleic anhydride grafted polypropylene (MA‐g‐PP) as a compatibilizer. At a first stage, modified polypropylenes (mPP) were used for an extrusion impregnation process, for the preparation of composite pellets containing about 70 wt% of SF. SF/mPP pellets with a large aspect ratio were prepared by continuous extrusion impregnation of a continuous SF yarn, using a single screw extruder and an adequate impregnation die. The mPP used were MA‐g‐PP and regular polypropylene (PP), modified by reaction with different amounts of an organic peroxide. The composite pellets were thus dry blended with regular PP pellets in an injection machine hopper, and injection molded to obtain composite tensile specimens with a minimum quantity of modified polypropylene, minimum fiber breakage and thermal degradation, and excellent mechanical properties. It is shown that the fiber breakage is reduced to a minimum, even for recycled composites, due to the presence of the low‐viscosity polymer layer wetting the SF fibers. The bulk composite effective viscosity and the fiber breakage extent and thermal degradation during the injection‐molding step are found to be closely related. Blending with much less expensive mPP at the impregnation stage optimizes the amount of expensive MA‐g‐PP. POLYM. ENG. SCI., 45:613–621, 2005. © 2005 Society of Plastics Engineers     

Rheological and mechanical behavior of long‐polymer‐fiber reinforced thermoplastic pellets

Polymer–polymer materials consist of a thermoplastic matrix and a thermoplastic reinforcement. Recent research activities concentrate on the manufacturing of semi‐finished polymer–polymer materials in other shapes than the commercially available tapes and sheets. In particular, a pellet‐like form provides the possibility of processing the polymer–polymer material by injection and compression molding. Nevertheless, the thermoplastic reinforcement is vulnerable to excessive heat and the processing usually needs special attention. The current study investigates the processing of long‐polymer‐fiber reinforced thermoplastic pellets, namely polypropylene‐polyethylene terephthalate and a single‐polymer polyethylene terephthalate, by extrusion for subsequent compression molding applications. The flow characteristics of the material as well as the preservation of the polymer reinforcement can be handled by accurate temperature control. The tensile and impact properties decrease with increasing process temperature though. Moreover, the results prove that the use of a common long‐fiber reinforced thermoplastic process chain is applicable to the newly developed polymer–polymer material. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 39716.     

Aspects of foaming a glass‐reinforced polypropylene with chemical blowing agents

This work explores the influence of a chemical blowing agent on different aspects of producing a short glass‐fiber‐reinforced polypropylene foam, examining the rheology of the system, the developed morphology of the part, and the resulting mechanical properties. Two different forms of an endothermic blowing agent, namely powder versus masterbatch, were compared to determine their effects on the process history and properties of an injection molded part. Samples were produced on an injection molding machine between 230 and 270°C using the low‐pressure foaming technique. Rheology of the resulting plasticized melt by the two different blowing agents was measured on an in‐line rheometer, showing a greater reduction in shear viscosity for the masterbatch additive, which correspondingly reduced the extent of fiber breakage observed. The final molded samples were analyzed for their foam structure (i.e., cell size, cell density, and skin thickness) as well as the properties of the glass fibers incorporated (namely, fiber length distribution). Tensile properties were found to diminish with increasing blowing agent content, though differences were observed based on the type of CBA used despite the similarities in foam structure produced. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 102: 4696–4706, 2006     

On‐line mixing during injection and simultaneous curing in liquid composite molding processes

Liquid composite molding (LCM) processes such as resin transfer molding (RTM) and vacuum assisted RTM (VARTM) are used to manufacture high quality and net‐shape fiber reinforced composite parts. All LCM processes impregnate fiber preforms packed in a mold cavity with a thermoset resin. After the preform is fully saturated, the injection is discontinued but the resin continues to cure. Once the curing step is complete, the part is de‐molded. The resin has to be mixed with a curing agent to cure. Typically, the resin and the curing agent are mixed together in a pressure pot before the injection. This has several disadvantages, such as storage of large amounts of hazardous polymerizing resin, wastage, and cleaning of cured resin from the injection line. This paper proposes the implementation and calibration of an alternative to this technique. The approach is to mix the curing agent with the resin as the resin enters the mold through a separate system featuring two feed‐lines. Such a system will enable one to maintain a uniform gel time throughout the part by varying the mixing ratio of resin and the catalyst during the injection. An experimental study of such on‐line mixing to obtain simultaneous curing and to reduce the overall curing time is conducted and presented in this paper. Implementation of a control scheme that varies the curing agent during injection and its effect on cure time is benchmarked with the process in which the percentage of curing agent is held constant. The gel time for the fabricated parts was reduced by 20–25% by continuously varying the percentage of curing agent during injection. POLYM. COMPOS., 26:74–83, 2005. © 2004 Society of Plastics Engineers     

Wood‐fiber‐reinforced poly(lactic acid) composites: Evaluation of the physicomechanical and morphological properties

This article presents the results of a study of the processing and physicomechanical properties of environmentally friendly wood‐fiber‐reinforced poly(lactic acid) composites that were produced with a microcompounding molding system. Wood‐fiber‐reinforced polypropylene composites were also processed under similar conditions and were compared to wood‐fiber‐reinforced poly(lactic acid) composites. The mechanical, thermomechanical, and morphological properties of these composites were studied. In terms of the mechanical properties, the wood‐fiber‐reinforced poly(lactic acid) composites were comparable to conventional polypropylene‐based thermoplastic composites. The mechanical properties of the wood‐fiber‐reinforced poly(lactic acid) composites were significantly higher than those of the virgin resin. The flexural modulus (8.9 GPa) of the wood‐fiber‐reinforced poly(lactic acid) composite (30 wt % fiber) was comparable to that of traditional (i.e., wood‐fiber‐reinforced polypropylene) composites (3.4 GPa). The incorporation of the wood fibers into poly(lactic acid) resulted in a considerable increase in the storage modulus (stiffness) of the resin. The addition of the maleated polypropylene coupling agent improved the mechanical properties of the composites. Microstructure studies using scanning electron microscopy indicated significant interfacial bonding between the matrix and the wood fibers. The specific performance evidenced by the wood‐fiber‐reinforced poly(lactic acid) composites may hint at potential applications in, for example, the automotive and packaging industries. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 102: 4856–4869, 2006     

Mechanical properties of injection molded long fiber polypropylene composites,Part 1: Tensile and flexural properties

Innovative polymers and composites are broadening the range of applications and commercial production of thermoplastics. Long fiber‐reinforced thermoplastics have received much attention due to their processability by conventional technologies. This study describes the development of long fiber reinforced polypropylene (LFPP) composites and the effect of fiber length and compatibilizer content on their mechanical properties. LFPP pellets of different sizes were prepared by extrusion process using a specially designed radial impregnation die and these pellets were injection molded to develop LFPP composites. Maleic‐anhydride grafted polypropylene (MA‐g‐PP) was chosen as a compatibilizer and its content was optimized by determining the interfacial properties through fiber pullout test. Critical fiber length was calculated using interfacial shear strength. Fiber length distributions were analyzed using profile projector and image analyzer software system. Fiber aspect ratio of more than 100 was achieved after injection molding. The results of the tensile and flexural properties of injection molded long glass fiber reinforced polypropylene with a glass fiber volume fraction of 0.18 are presented. It was found that the differences in pellet sizes improve the mechanical properties by 3–8%. Efforts are made to theoretically predict the tensile strength and modulus using the Kelly‐Tyson and Halpin‐Tsai model, respectively. POLYM. COMPOS., 28:259–266, 2007. © 2007 Society of Plastic Engineers     

Fiber breakage and dispersion in carbon‐fiber‐reinforced nylon 6/clay nanocomposites

In this paper, short carbon‐fiber‐reinforced nylon 6/clay nanocomposites are prepared via melt compounding, and fiber breakage and dispersion during processing are studied. The influences of clay and processing conditions on fiber breakage and dispersion are taken into consideration. It is found that the presence of organoclay can improve fiber dispersion, which is due to dispersion at the nanoscale of exfoliated clay sheets with large aspect ratio. The bimodal distribution of fiber length is observed in fiber‐reinforced nanocomposites, which is similar to that in conventional fiber‐reinforced composites. The improvement of fiber breakage at moderate organoclay loadings is also observed, which is ascribed to the rheological and lubricating effects induced by organoclay. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci, 2007     

Development and characterization of flax fiber reinforced biocomposite using flaxseed oil‐based bio‐resin

In this study, acrylated epoxidized flaxseed oil (AEFO) resin is synthesized from flaxseed oil, and flax fiber reinforced AEFO biocomposites is produced via a vacuum‐assisted resin transfer molding technique. Different amounts of flax fiber and styrene are added to the resin to improve its mechanical and physical properties. Both flax fiber and styrene improve the mechanical properties of these biocomposites, but the flexural strength decreases with an increase in styrene content. The mass increase during water absorption testing is less than 1.5% (w/w) for all of the AEFO‐based biocomposites. The density of the AEFO resin is 1.166 g/cm³, which increases to 1.191 g/cm³ when reinforced with 10% (w/w) flax fiber. The flax fiber reinforced AEFO‐based biocomposites have a maximum tensile strength of 31.4 ± 1.2 MPa and Young's modulus of 520 ± 31 MPa. These biocomposites also have a maximum flexural strength of 64.5 ± 2.3 MPa and a flexural modulus of 2.98 ± 0.12 GPa. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 41807.     

Effects of thermoplastic elastomer on the morphology and mechanical properties of glass fiber‐reinforced polycarbonate/acrylonitrile–butadiene–styrene

This article investigated the influence of thermoplastic elastomer like acrylonitrile–butadiene–styrene (ABS) high rubber powder (HRP), and ethylene methylacrylate (EMA) on the mechanical performances, flow ability, and morphology of glass fiber‐reinforced polycarbonate (PC)/ABS blends. Blending was carried out through a twin‐screw extruder, and all testing specimens were shaped by an injection molding machine. Experimental results showed that the toughening effect of EMA was more obvious than HRP due to fracture mechanism like crazing, shear yielding occurred in corporation with EMA. About 15 wt% glass‐fiber (GF) reinforcement and 6 wt% EMA toughening can get a balanced behavior among strength, stiffness, and toughness for superior performance of the polymer. POLYM. ENG. SCI., 59:E144–E151, 2019. © 2018 Society of Plastics Engineers     

Short Fiber orientation and its Effects on the Properties of Thermoplastic Composite Materials

I. INTRODUCTION

While it is true that preform processes involving the use of long or continuous fibers are known and used in the manufacture of reinforced thermoplastic articles–Azdel [1] or STX sheet [2], for example–it is generally the case that such articles are formed by injection molding. Both the feedstock requirements for this process and the occurrence of high melt shear during it ensure that only short fibers will be present in the finished article. Although the use of slow screw speeds, slow injection rates, low back pressure, wide sprues, runners, and gates, and large radii of curvature avoids fiber breakage during molding, such conditions are not often found in practice. Furthermore, the necessity of incorporating reground material into the feedstock also ensures short fiber lengths in the final part, lengths not greatly in excess of the critical length required for effective stress transfer from polymer matrix to reinforcing fiber. In a practical part, design uncertainties caused by fiber length attrition are further compounded by the effects of fiber orientation. Although length distribution effects have been studied by a number of workers, both experimentally [3] and theoretically [4], relatively little has been reported on orientation effects in short fiber reinforced thermoplastics.     

粉末浸渍长玻璃纤维增强聚丙烯的注塑

采用粉末浸渍的方法制备连续玻璃纤维增强聚丙烯预浸料,经切割获得长纤维增强聚丙烯粒子,探索了材料的注塑工艺,研究了注塑后材料的力学性能及其影响因素。结果表明,粉末浸渍的长纤维增强聚丙烯经注塑后可获得力学性能的制品;随着预浸料切割长度的增长、纤维含量的增加,材料的力学性能提高;在基体聚丙烯中添加接枝极性基团的功能化聚丙烯,可改善体系的界面结合,提高材料的力学性能,但功能化聚丙烯的含量超过一定值后,材料的冲击强度有所下降;控制注塑时的模具温度,可以改变材料的一些力学性能。     

Adhesive strengths between glass fiber‐filled ABS and metal in insert molding with engraved and embossed metal surface treatments

Metal and plastic can be bonded in a single molding process by metal insert molding, in which a metal is inserted into a mold and a plastic resin is then injected. However, the adhesive strength at the interface between the metal and plastic is weakened by the difference in the shrinkage ratio and inherent differences between the materials in the metal insert molding. This study reports the treatment of a metal surface that is followed by inserting the metal into a mold to increase the adhesive strength between the metal and glass fiber (GF)‐filled acrylonitrile butadiene styrene (ABS). A laser process was used for an engraving surface treatment and a plating process was performed for an embossed surface treatment of the metal. In addition, the adhesive strength between the metal and GF‐filled ABS was evaluated after the insert molding process was completed. Particles such as glass beads, ceramic beads, artificial diamonds, and aluminum oxides were employed in the plating process. The adhesive strength varied depending on the surface treatment of the metal. In particular, the adhesive strength significantly increased when an undercut shape was formed at the metal surface. The best adhesive strength with GF‐filled ABS was found in the metal specimen plated using aluminum oxide particles. POLYM. ENG. SCI., 59:E93–E100, 2019. © 2018 Society of Plastics Engineers