Squeeze flow testing of glass mat thermoplastic material

The anisotropic flow behaviour of glass fibre/polypropylene glass mat thermoplastic (GMT) has been investigated using axisymmetric squeeze flow testing between parallel circular plates. The material has a continuous swirled fibre mat construction and is manufactured by the melt-impregnation technique. Constant plate velocity squeeze flow tests have been carried out under isothermal conditions to cover a range of strain rates. Modelling of squeeze flow behaviour has been based on two simple expressions: one assumes pure shear flow during testing, while the other assumes pure biaxial extension (plug flow). The modelling results suggest that biaxial extension dominates the isothermal squeeze flow process, with apparently negligible shear flow effects.     

Fatigue performance characterisation of resistance-welded thermoplastic composites

This study investigates the fatigue performance of resistance-welded thermoplastic composites. Lap shear specimens consisting of unidirectional carbon fibre/poly-ether-imide (CF/PEI), unidirectional carbon fibre/poly-ether-ketone-ketone (CF/PEKK) and 8-harness satin weave fabric glass fibre/poly-ether-imide (GF/PEI) composites were resistance-welded using a metal mesh heating element. The specimens were fatigue-tested at various percentages of their static lap shear strengths at a load ratio R = 0.1 and frequency f = 5 Hz. The fatigue performances of resistance-welded semi-crystalline (PEKK) and amorphous (PEI) composites were compared and the failure modes of the specimens were described. The stiffness degradation was monitored during the tests in order to evaluate the damage accumulation in the specimens. Linear stress-life (S–N) curves were obtained for all three materials when plotted on a semi-log scale. Interlaminar failure modes, involving tearing of the heating element and damage to the adherends were observed. The indefinite fatigue lives of CF/PEKK and CF/PEI welded specimens were obtained at 25% of their static lap shear strengths. The indefinite fatigue life of the GF/PEI welded specimens was obtained at 20% of the static lap shear strength.     

Remotely actuated polymer nanocomposites--stress-recovery of carbon-nanotube-filled thermoplastic elastomers

Stimuli-responsive (active) materials undergo large-scale shape or property changes in response to an external stimulus such as stress, temperature, light or pH. Technological uses range from durable, shape-recovery eye-glass frames, to temperature-sensitive switches, to the generation of stress to induce mechanical motion. Here, we demonstrate that the uniform dispersion of 1-5 vol.% of carbon nanotubes in a thermoplastic elastomer yields nanocomposites that can store and subsequently release, through remote means, up to 50% more recovery stress than the pristine resin. The anisotropic nanotubes increase the rubbery modulus by a factor of 2 to 5 (for 1-5 vol.%) and improve shape fixity by enhancing strain-induced crystallization. Non-radiative decay of infrared photons absorbed by the nanotubes raises the internal temperature, melting strain-induced polymer crystallites (which act as physical crosslinks that secure the deformed shape) and remotely trigger the release of the stored strain energy. Comparable effects occur for electrically induced actuation associated with Joule heating of the matrix when a current is passed through the conductive percolative network of the nanotubes within the resin. This unique combination of properties, directly arising from the nanocomposite morphology, demonstrates new opportunities for the design and fabrication of stimuli-responsive polymers, which are otherwise not available in one material system.     

Fatigue failure characterisation of resistance-welded thermoplastic composites skin/stringer joints

An experimental investigation characterising the fatigue failure mechanisms of resistance-welded thermoplastic composites skin/stringer joints is presented. Unidirectional (UD) and quasi-isotropic adherends were welded using stainless steel meshes as heating elements. The specimen geometry consisted of a flange laminate, representing a stringer, welded onto a skin laminate. In order to avoid current leakage to the electrically conductive adherends, a ceramic-coated heating element (TiO₂ HE) was used for welding the UD specimens and some of the quasi-isotropic specimens. The fatigue performance of the welded joints was investigated under three-point bending. An indefinite fatigue life was obtained at 40% and 35% of the static damage initiation load for the UD and quasi-isotropic specimens, respectively. The failure mechanisms were documented based on observation of the fatigue cracks initiation and growth. UD specimens failed at the weld interface while quasi-isotropic specimens showed delaminations both in the flange or skin laminates and at the weld interface. The TiO₂ HE did not show any fatigue mechanical performance reduction. However, debonding at the weld interface was shown to occur between the metal mesh wires and the TiO₂ coating instead of between the laminates and the weld.     

A review of thermoplastic polymer foams for functional applications

Journal of Materials Science - Recently, functional applications of thermoplastic foams have received extensive attention from the research and materials communities, focusing on their various...     

Shear characterisation of uni-directional fibre reinforced thermoplastic melts by means of torsion

Intra-ply shear appears during the forming process of hot thermoplastic laminates with a uni-directional fibre reinforcement. This paper proposes a torsion bar test to characterise the longitudinal shear mechanism, which can be performed with a standard rheometer. Sensitivity analyses showed that most reliable shear property measurements can be obtained by using torsion bar specimens with a close to square cross section. The method is implemented in practise and critically evaluated. Storage and loss moduli were determined for carbon UD/PEEK specimens at high temperatures. Non-linear material behaviour was found for relatively small shear strains. The linear regime was focussed on subsequently, where the characteristics were found to be similar to that of a visco-elastic solid or weak gel, confirmed by a dominant storage modulus and a weak frequency dependency. Future work is recommended to be focussed on the large strain regime, for which this paper provides a found basis.     

Synthesis and characterization of a novel biodegradable thermoplastic shape memory polymer

A novel poly(urethane-urea) shape memory polymer (PUU SMP) was synthesized from poly(DL-lactic acid) (PDLLA) Diols, hexamethylene diisocyanate(HDI) and butanediamine(BDA), aiming to develop a biodegradable and biocompatible shape memory polymer. Its structure, thermal properties and shape-memory behaviors were characterized through Fourier transform infrared spectrometry (FTIR), differential scanning calorimetry (DSC) and bending test. The results showed that the response temperature for shape memory of PDLLA–PUU SMP is dependent on the polymeric glass transition temperature and this polymer has an excellent shape memory effect, having the ratio of the shape-memory fixation approximately 100% and the ratio of the shape-memory recovery about 98%.     

Valorisation of macroalgae industrial by-product as filler in thermoplastic polymer composites

Poly(lactic acid) composites filled with algae industrial by-product were prepared using melt-mixing process at filler weight fractions of 20, 30 and 40 wt%. Algae by-products were after the extraction of alginate (AW) and mixed with diatomaceous earth (DE). The composition and morphology of both fillers were analysed. Composites’ mechanical properties and thermal degradation were investigated as a function of filler type and content. The addition of DE-filler at 40 wt% resulted in the increase of Young’s modulus by 20% compared to the neat PLA. The presence of small DE particles improved stress distribution and led to stronger composites as compared with AW-filled. Cold crystallization of PLA was induced by small algae particles. Thermal degradation of all composites started at lower temperatures compared with neat PLA. A glow-wire test was carried out to evaluate the effect of inorganic matter on the ignition of the material.     

Repetitive flow forming of wood impregnated with thermoplastic binder

A processing technique for applying plastic deformation to a solid wood has been developed. In the present study, the effects of repetitive flow forming on the fluidity of solid wood materials impregnated with thermoplastic binder and on the mechanical properties of the products were investigated. The results showed that the increase in the number of extrusions decreased the load of the starting point of the extrusion especially in the lower polymer content of the wood materials. The bending strengths of the products were decreased with the repetitive extrusion using the lower polymer content (less than approximately 50 %) of the materials. On the other hand, the strength with higher polymer content (more than approximately 50 %) increased with the repetitive extrusion. The wood particles were found to become smaller in size with the repetitive extrusion. The tangles of the wood particles were also observed in higher polymer content of the materials. It was speculated that these configuration changes during reprocessing strongly affect both the fluidity during the extrusion and the mechanical properties of the products.     

改性处理对热塑性聚合物基复合材料性能的影响

研究了冷却方式及改性处理对玻纤增强热塑性聚合物复合材料性能的影响.采用模压工艺制备复合材料,研究冷却方式、偶联剂处理及等离子改性处理对玻纤增强聚丙烯力学性能的影响,并通过DSC分析复合体系结晶性能的变化规律.结果表明:采用同加热板一起冷却的复合材料结晶性能较好,材料的拉伸性能最高;改性处理在一定程度上改善了材料的界面结...     

Effects of thermal treatment on the tribological characteristics of thermoplastic polymer film

Friction tests were carried out using a microtribometer to investigate the effect of thermal treatment on microscale friction and wear between poly(methyl methacrylate) (PMMA) film and a fused silica lens. Two films were examined: one that was baked at 413 K for 2 min and one that was baked at 433 K for 24 h. The friction forces on the PMMA films were measured under atmospheric conditions as the temperature of the films was increased from 300 K to 443 K. The contact area between the films and the lens was also examined. As the temperature increased, the friction force increased for both films. The slope of the friction force with temperature and the contact area varied, depending on the state of the film surface; glassy, rubbery, and viscous flow states. The baking conditions also affected the slope, contact area, and wear generation. For temperatures at which the samples were in a glassy state, wear particles were not generated on the sample baked for 24 h. The results demonstrate that the tribological characteristics can be altered by the thermal treatment of the PMMA film as well as the temperature. When the film contains some residual solvent, the residual solvent in the PMMA film can diffuse to the PMMA surface due to heating and thus decrease the friction force under room-temperature conditions.     

Numerical characterisation of fullerene based polymer nanocomposites considering interface effects

In this investigation, the effective mechanical properties of fullerene nanocomposites considering interface effects were characterised. Load transfer in nanocomposite materials is achieved through the fullerene/matrix interface. Thus, to determine nanocomposite mechanical properties, the interface behaviour must be determined. A single fullerene and the surrounding polymer matrix are modelled. Two cases of perfect bonding and an elastic interface are considered. Two models are suggested for elastic interface. The first elastic interface model consists of a thin layer of an elastic material surrounding the fullerene. In the second elastic interface model, a series of spring elements are used as the fullerene/matrix interface. The results of numerical models indicate the importance of adequate interface bonding for a more effective strengthening of polymer matrix by fullerene. Also, Young’s modulus prediction for fullerene in epoxy matrix is compared to experimental data investigated by Rafiee et al. (2011), and good agreement is observed.     

Manufacture and characterisation of thermoplastic composites made from PLA/hemp co-wrapped hybrid yarn prepregs

PLA/hemp co-wrapped hybrid yarns were produced by wrapping PLA filaments around a core composed of a 400 twists/m and 25 tex hemp yarn (Cannabis sativa L) and 18 tex PLA filaments. The hemp content varied between 10 and 45 mass%, and the PLA wrapping density around the core was 150 and 250 turns/m. Composites were fabricated by compression moulding of 0/90 bidirectional prepregs, and characterised regarding porosity, mechanical strength and thermal properties by dynamic mechanical thermal analysis (DMTA) and differential scanning calorimetry (DSC). Mechanical tests showed that the tensile and flexural strengths of the composites markedly increased with the fibre content, reaching 59.3 and 124.2 MPa when reinforced with 45 mass% fibre, which is approximately 2 and 3.3 times higher compared to neat PLA. Impact strength of the composites decreased initially up to 10 mass% fibre; while higher fibre loading (up to 45 mass%) caused an increase in impact strength up to 26.3 kJ/m², an improvement of about 2 times higher compared to neat PLA. The composites made from the hybrid yarn with a wrapping density of 250 turns/m showed improvements in mechanical properties, due to the lower porosity. The fractured surfaces were investigated by scanning electron microscopy to study the fibre/matrix interface.     

Ultrasonic welding of thermoplastic composites: a numerical analysis at the mesoscopic scale relating processing parameters,flow of polymer and quality of adhesion

Ultrasonic continuous welding of thermoplastic composite plates is a very promising process of particular interest for the assembly of aeronautics large parts. Its modeling and simulation however suffers from the difficulty of accounting for the very different time scales that rule the thermo-mechanical phenomena at the level of the adhesion zone. This problem was addressed in our previous works and led to an original simulation tool presented in Levy et al. (Eur J Mech A, Solids 30(4):501–509, 2011a). In this paper, the adopted time-homogenized multiphysical modeling of the flow at the mesoscopic scale of the energy directors is first presented. Then, using the numerical software in a 2D approach, an extensive numerical parametric study of the process is presented. The phenomena allowing welding are confirmed to be an initial strain concentration in the energy director, and the formation of a flowing fold. The influence of the following process parameters are finally investigated: amplitude of vibrations, holding force of the sonotrode, thickness of the plates, radius of curvature at the tip of the director, angle of the director. Process efficiency and weld quality is evaluated through simple indicators such as the equivalent stiffness analysis, the healing degree and the risk of porosity entrapment. The present study, carried at the mesoscopic scale, provides a better understanding of the complex interactions between physical and process parameters and enables to draw important technological conclusions for the design of energy directors.     

Thermal properties of thermoplastic starch/synthetic polymer blends with potential biomedical applicability

Previous studies shown that thermoplastic blends of corn starch with some biodegradable synthetic polymers (poly(-caprolactone), cellulose acetate, poly(lactic acid) and ethylene-vinyl alcohol copolymer) have good potential to be used in a series of biomedical applications. In this work the thermal behavior of these structurally complex materials is investigated by differential scanning calorimetry (DSC) and by thermogravimetric analysis (TGA). In addition, Fourier-transform infrared (FTIR) spectroscopy was used to investigate the chemical interactions between the different components. The endothermic gelatinization process (or water evaporation) observed by DSC in starch is also observed in the blends. Special attention was paid to the structural relaxation that can occur in the blends with poly(lactic acid) at body temperature that may change the physical properties of the material during its application as a biomaterial. At least three degradation mechanisms were identified in the blends by means of using TGA, being assigned to the mass loss due to the plasticizer leaching, and to the degradation of the starch and the synthetic polymer fractions. The non-isothermal kinetics of the decomposition processes was analyzed using two different integral methods. The analysis included the calculation of the activation energy of the correspondent reactions.     

On the characterisation of transverse tensile properties of molten unidirectional thermoplastic composite tapes for thermoforming simulations

The development of Finite Element (FE) thermoforming simulations of tailored thermoplastic blanks, i.e. blanks composed of unidirectional pre-impregnated tapes, requires the characterisation of the composite tape under the same environmental conditions as forming occurs. This paper presents a novel approach for the characterisation of transverse tensile properties of unidirectional thermoplastic tapes using a Dynamic Mechanical Analysis (DMA) system in a quasi-static manner. The relevance of the presented method is assessed by testing, under the same environmental conditions, a control material with both a universal testing machine and a DMA system. For simulation purposes, a unidirectional thermoplastic tape is characterised under environmental forming conditions using the presented test method. Experimental results, which include stress–strain behaviour and transverse viscosity, are eventually used to identify, via an inverse approach, simulation parameters of a thermo-visco-elastic composite material model (MAT 140, PAM-Form, ESI Group). Comparisons between simulated and experimental results show good agreement.     

Preparation,characterisation and antimicrobial activities of polymer/realgar nanocomposites

Preparation and study of homogeneous nanoparticles (NPs) have been an important area of research in recent years. In this work, we describe a polymer-protected method for the preparation and formation of realgar nanocomposites with various average diameters. Two types of macromolecules were selected and their interactions with nanorealgar were studied by spectrometric methods. It is found that the starch has a significant effect on the formation and growth of homogeneous nanorealgar with an average diameter of 30?nm. In the case of using polyvinylpyrrolidone (PVP) as a protecting polymer, the realgar NP size is in the range of 20–80?nm, with an average value of 55?nm. The polymer-protected nanorealgar shows superior antimicrobial activity against Escherichia coli and Staphylococcus aureus, whereas the bulky realgar colloid formed in aqueous solution has much less antimicrobial activity. The antimicrobial activity followed the order As₄S₄–starch NPs?>?As₄S₄–PVP NPs?>?As₄S₄ NPs, which suggests small realgar NPs are more favourable.     

Spherulitic morphology of the matrix of thermoplastic PEEK/carbon fibre aromatic polymer composites

PEEK/carbon fibre composites (derived from APC-2) have been examined with a permanganic etching technique in order to reveal the crystalline, spherulitic morphology of the thermoplastic PEEK polymer matrix. The locations of the nucleation sites for spherulite growth have been categorized. Nucleation can occur both within the matrix and from the carbon fibres. Crystallization at lower temperatures favours matrix nucleation. Nucleation from fibres is dominated by sites associated with fibre-fibre contact. There is no evidence of “transcrystalline” growth. The study also identifies two types of crystal orientation effect in the polymer matrix. The first is a slight orientation that can occur in standard mouldings and is the result of the fibres constraining the shape of the volume into which spherulite growth can occur. The second effect produces abnormally high crystal orientation and is the result of improper processing at too low a melt temperature. Such conditions cause self-seeding during consolidation of laminates which, coupled with flow-induced orientation, can lead to directionally arranged spherulite precursors in different stages of morphological development.