Measuring spatial orientation of short fiber reinforced thermoplastics by image analysis

A computer based measuring strategy to determine spatial orientation of short glass fibers from the cross-section of single fibers is presented. A practicable way of correcting the inclination-dependent probability of hitting a fiber is shown as well as the correction of fiber-end intersections. The latter is done by pattern recognition and application of a set of FORTRAN subroutines. A simple model allows the approximate calculation of thermal expansion as a function of volume content and fiber orientation. This serves as an applicability test for the measuring system.     

Weld-line characteristics in short fiber reinforced thermoplastics

Fibers can greatly improve the mechanical properties of polymers but may also severely weaken molded parts at their weld-line compared to their bulk strength. The tensile properties and fiber orientation of injection and compression molded fiber reinforced Noryl and polypropylene samples with and without a weld-zone were studied. Distinct differences in structure and mechanical properties of weld-containing and weld-free samples were identified. In unfilled Noryl and unfilled polypropylene, the presence of a weld-line was found to only have a small effect on the tensile strength and modulus, while in the corresponding fiber reinforced systems, orientation of the fibrous reinforcement parallel to the weld-line caused a significant reduction of the tensile strength compared to the weld-free products. The strength ratio of welded and unwelded specimens was found to decrease with increasing fiber concentration. Quantitative determination of the glass fiber orientation distribution within the weld-line region and in the bulk was carried out by analyzing photomicrographs of polished sections at desired locations.     

Strength of short fiber reinforced polymers: Effect of fiber length distribution

In this study, the prediction of mechanical strength of short fiber reinforced plastics (SFRPs) is made possible by obtaining a Fiber Length Distribution (FLD) efficiency factor, η_FLD, from the formerly known twofold discrete strengthening equation of Kelly–Tyson. The unified parameter η_FLD is developed involving both the effects of fiber breakage and resulting distribution, fiber volume fraction and fiber and interface properties, so that they can be incorporated into modified rule of mixtures (MROM). This procedure helps to clarify the experimentally observed loss in strengthening rate with increasing fiber fraction. By adapting a few experimentally determined distributions to a Weibull type function, the analytical solutions described in this study establish the exploration of the strength of SFRPs in the entire fiber content range or can reveal the interfacial bond strength. After investigating the effects of fiber and interface parameters on strengthening efficiency, it is found that common fiber‐matrix combinations possessing intermediate critical fiber lengths show a significant decrease in strengthening efficiency with increasing fiber content at low fiber loadings. On the contrary, higher and lower critical fiber lengths yield less significant losses. POLYM. COMPOS., 2008. © 2008 Society of Plastics Engineers     

Rheological behavior and fiber orientation in slit flow of fiber reinforced thermoplastics

The flow behavior and fiber orientation in slit flow of a short fiber reinforced thermoplastic composite melt are investigated. A slit die with adjustable gap and interchangeable entrance geometries was designed and built. The slit die is fed by a single screw extruder. The bulk viscosity is calculated from the axial pressure profiles measured using three flush mounted pressure transducers. The effect of entrance geometry and gap dimensions on the fiber orientation and bulk flow behavior is specifically considered. A skin-core composite fiber orientation is observed in the thickness direction. Fibers are oriented in the flow direction and parallel to the walls in the skin region irrespective of the entrance geometry. Different fiber orientation distributions in the core region can be realized by using different entrance geometries. However, the changes in the core fiber orientation are not fully reflected by the measured viscosities, due to highly oriented skin layer. Exit pressures obtained by extrapolation of linear pressure profiles are found to be all positive, but dependent on the die geometry and entrance conditions, even for the unfilled melts.     

Description and modeling of fiber orientation in injection molding of fiber reinforced thermoplastics

As mechanical properties of short fiber reinforced thermoplastic injected components depend on flow induced fiber orientation, there is considerable interest in validating and improving models which link the flow field and fiber orientations to mechanical properties. The present paper concerns firstly the observation and quantification of fiber orientation in a rectangular plaque with adjustable thickness and molded with 30 and 50 wt% short fiber reinforced polyarylamide. An automated 2D optical technique has been used to determine fiber orientations. A classical skin (with orientation parallel to the flow)-core (with orientation perpendicular) structure is observed for thick plaques (thickness greater than 3 mm) but the core region is fragmentary for thickness less than 1.7 mm. It is shown that the gate design and different levels of fiber interactions, due to different fiber concentrations, are responsible for these observations. Secondly, computer simulations of flow and fiber orientation are shown. The agreement with the actual data is good, except in the case of the core for thin plaques. The limitations that have to be resolved come not only from the standard fiber orientation equations, but also from the flow kinematics computation.     

Effect of glass fiber length on the creep and impact resistance of reinforced thermoplastics

Impact and flexural creep testing were conducted at temperatures between −22°F (−30°C) and 250°F (121°C) to evaluate and compare the end-use performance of continuous long glass fiber-reinforced thermoplastic sheet composites to that of short glass fiber-reinforced thermoplastics. The matrices studied consisted of amorphous (polycarbonate and acrylonitrile-butadiene-styrene) and semicrystalline (polypropylene) polymers. Data were obtained from both injection-molded specimens (short fibers), and from specimens machine-cut from compression-molded test panels (continuous long fibers). The creep results of this study demonstrated that continuous long fibers are more efficient than short fibers in reinforcing the thermoplastic matrices, resulting in enhanced load-bearing ability at elevated temperatures. The addition of continuous long glass fibers to the thermoplastic matrices led to a significant increase in the notched Izod impact strengths between the temperatures of −22°F (−30°C) and 77°F (25°C), and only slight improvement in the drop-weight impact strengths. The lack of correlation between notched Izod impact and drop-weight strengths is largely due to the difference in crack propagation and fracture initiation energies. Results of the Rheometrics instrumented impact test indicated a higher total fracture energy for the long glass-reinforced thermoplastic sheet composites than for the short glass-reinforced injection-molded thermoplastics. The decreased ease of crack propagation in thermoplastic sheet composites is associated with the high energy-absorbing mechanisms of fiber debonding and interply delamination. The results of this study point to the significant property improvement of continuous long fibers vs. short fibers. The creep strength of short fiber-reinforced thermoplastics are greatly affected by the nature of the stress transfer which in turn is influenced by the critical fiber length and temperature, which is not the case for the long fiber-reinforced thermoplastic sheet composites. Long fibers dramatically increase the impact resistance of thermoplastics. The retention of toughness at low temperatures coupled with elevated temperature performance greater than similar short glass fiber-reinforced thermoplastics effectively extends the capabilities of thermoplastic sheet composites at both temperature extremes.     

Mechanical properties of discontinuous fiber reinforced thermoplastics. II. Random-in-plane fiber orientation

The mechanical properties are presented for a series of discontinuous fiber-reinforced thermoplastic composites made with random-in-plane fiber orientation. The matrix and fiber materials were chosen to provide a wide range of strength, modulus, ductility and adhesive properties. In many cases strong, rigid, yet tough composites were fabricated. Strength levels of over 20,000 psi and modulus values over 1,000,000 psi were reached in several systems reinforced with short Kevlar-49 and graphite fibers. A strong dependence of composite strength and modulus on fiber strength and modulus was noted indicating good transfer of load from matrix to reinforcement. Fiber efficiency factors for modulus and strength were calculated for the experimental composite systems and averaged 0.19 and 0.11 respectively. Data were analyzed using basic composite theory. Properties of the experimental composites could not be predicted from constituent properties.     

Effects of fiber compression and length distribution on the flexural properties of short kenaf fiber‐reinforced biodegradable composites

The effects of the fiber compression and the length distribution on the flexural properties of short kenaf fiber‐reinforced biodegradable composites were investigated. Two types of kenaf (KU and KT) that were different in the density and the length distribution were used as reinforcements. These fibers were mixed with a corn–starch‐based resin, and the composite specimens were fabricated by a hot press forming. The flexural modulus in the KU specimens was not different from that in the KT, despite the difference of the fiber Young's modulus (KU 14.5 GPa and KT 22.1 GPa). This was because the KU was compressed more than the KT in the composite specimen because of the lower density structure. However, in the longest fiber (10.5 mm), the flexural strength in the KT specimens was considerably higher by 67% than that in the KU. The reason was that the KT did not include the fibers below the critical length (4.2 mm) because of the narrower fiber distribution than the KU. In fact, the flexural strength in the KT specimen significantly decreased with decrease in the average fiber length, which included the fibers below the critical length. Moreover, the flexural modulus agreed well with the calculated values by Cox's model that incorporated the effect of the fiber compression. POLYM. COMPOS. 27:170–176, 2006. © 2006 Society of Plastics Engineers     

A study of the tensile modulus of short fiber reinforced plastics

An experimental study of the tensile modulus of unidirectional short fiber reinforced plastics is reported. The data show poor agreement with the theories for the longitudinal case but better agreement in the other cases. A semi-empirical theory is proposed to explain the longitudinal modulus data.     

Fiber orientation control of short‐fiber reinforced thermoplastics by ram extrusion

In this study we examine the fiber orientation distribution, fiber length and Young's modulus of extruded short‐fiber reinforced thermoplastics such as polypropylene. Axial orientation distributions are presented to illustrate the influence of extrusion ratio on the orientation state of the fibrous phase. Fibers are markedly aligned parallel to the extrusion direction with increasing extrusion ratio. The orientation state of extruded fiber‐reinforced thermoplastics (FRTP) is almost uniform throughout the section. The control of fiber orientation can be easily achieved by means of ram extrusion. Experimental results are also presented for Young's modulus of extruded FRTP in the extrusion direction. Young's modulus follows a linear trend with increasing extrusion ratio because the degree of the molecular orientation and the fiber orientation increases. The model proposed by Cox, and Fukuda and Kawada describes the effect of fiber length and orientation on Young's modulus. The value of the orientation coefficient is calculated by assuming a rectangular orientation distribution and calculating the fiber distribution limit angle given by orientation parameters. By comparing the predicted Young's modulus with experimental results, the validity of the model is elucidated. The mean fiber length linearly decreases with increasing extrusion ratio because of fiber breakage due to plastic deformation. There is a small effect on Young's modulus due to fiber breakage by ram extrusion.     

Weld line improvement of short fiber reinforced thermoplastics with a movable flow obstacle

Short fiber reinforced (SFR) thermoplastics are ideal materials from which to manufacture complex technical parts in high volumes with low energy expenditure. The orientation of the fibers, and hence their reinforcing effect, depends strongly on the nature of the cavity and on the injection molding process. One disadvantage of SFR thermoplastics is a significant decrease in mechanical properties in the areas of the weld lines, due to subopt imal fiber orientation as the melt streams reunite at these points. Common mold‐based and process‐based optimization techniques alter the fiber orientation after the formation of the weld line. The mold‐based approach presented here, on the other hand, operates at the time the weld line is formed: by redirecting the melt streams, it moves the weld line and improves the fiber orientation. A prototype mold is described, and samples produced from it with both standard and modified weld lines are compared with flawless specimens. The new technique yields a large rise in flexural strength and a smaller but significant improvement in tensile properties. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 42025.     

Rheology of short fiber filled thermoplastics

We examine the applicability of the conformation tensor to describe the fiber orientation and rheology of moderately concentrated fiber-filled thermoplastics subjected to large deformation flow. To retain computational simplicity, we assume a Newtonian matrix. We present a model that can account for orientation effects, Brownian motion, semiflexibility, and interactions through excluded volume effect, of the fibers. The model predicts a wide variety of rheological effects. We present predictions of steady shear viscosity, primary normal stress and the creep functions, as well as uniaxial elongational viscosity, due to the fibers. We have compared rheological data for 9.54 wt% carbon fibers in polyethylene and 30 wt% glass fibers in polypropylene, with the model predictions. By defining an “effective fiber concentration,” we have been able to correlate the model well with data. With fitting parameters from the steady state viscosity vs. shear rate data, we have been able to predict the steady state primary stress coefficient data as well as the creep data.     

The elastic properties of random-in-plane short fiber reinforced polymer composites

Four types of random-in-plane short fiber reinforced polymer composites were manufactured by the prepreg route using carbon or glass fiber tissue and 913 or 924 epoxy resin. The in-plane Young's modules and in-plane shear modulus of the composites were measured over the temperature range − 100 to + 200°C by dynamic mechanical analysis using three point bend and rectangular torsion testing geometries. Theoretical predictions of the elastic properties of the composites were determined over the same temperature range and compared with the experiment. Of particular interest was the use of the “S mixing rule” of McGee and McCullough to determine a single theoretical estimate for the composite elastic properties. Excellent agreement between experiment and theory was found for the four composites over the majority of the measured temperature range.     

Some features of the injection molding of short fiber reinforced thermoplastics in center sprue-gated cavities

This paper describes an investigation into the fiber orientation in a number of center sprue fed cavities in short glass fiber filled polypropylene and nylon. The data have been interpreted in terms of a generalized five-layer structure resulting from the frozen skin formation and the high and low shear levels in the flowing melt. The implications for scaling up the mold size are discussed from the results obtained with different shot volumes. The fiber structure was observed to depend on location in the molding, local injection time, and injection rate. In addition the occurrence of fiber-free layers within the moldings using the filled polypropylene increases with an increase in shot volume, which produces an inherent ‘scale-up’ problem. Notwithstanding the mold geometry subtleties, the fiber orientation in all the moldings follows similar patterns and trends.     

Effect of packing pressure on fiber orientation in injection molding of fiber‐reinforced thermoplastics

Injection molding of fiber‐reinforced polymeric composites is increasing with demands of geometrically complex products possessing superior mechanical properties of high specific strength, high specific stiffness, and high impact resistance. Complex state of fiber orientation exists in injection molding of short fiber reinforced polymers. The orientation of fibers vary significantly across the thickness of injection‐molded part and can become a key feature of the finished product. Improving the mechanical properties of molded parts by managing the orientation of fibers during the process of injection molding is the basic motivation of this study. As a first step in this direction, the present results reveal the importance of packing pressure in orienting the fibers. In this study, the effects of pressure distribution and viscosity of a compressible polymeric composite melt on the state of fiber orientation after complete filling of a cavity is considered experimentally and compared with the simulation results of Moldflow analysis. POLYM. COMPOS. 28:214–223, 2007. © 2007 Society of Plastics Engineers     

Injectin molding of short fiber reinforced thermoplastics in a center‐gated mold

We have studied injection molding of a rectangular box using short fiber reinforced polypropylene. The fiber orientation distribution and the local stiffness properties in radial and transverse directions have been measured in the bottom plane. The deduced orientation tensors are compared with predictions of a commercial computer code. Discrepancies are related to approximations made in the calculations and effects not accounted for by the present modeling approach. In the calculations the fiber interaction coefficient was varied seeking to fit experiments. We comment on the out‐of‐plane components of the orientation tensor, the relative thickness of skin and core layers, and the radial dependence of the fiber orientation in each layer. Values of the components of the 4^th‐order orientation tensor calculated from the measured orientation distribution are used to compare different closure approximations referred in the literature. Anisotropy in the stiffness properties, calculated form the measured fiber orientation, agree well with measurements.     

Fracture behavior of short fiber reinforced thermoplastics I. Crack propagation mode and fracture toughness

The fracture behavior of several short glass fiber reinforced thermoplastics has been studied. The fracture toughness of these materials may be related to local crack propagation mode, which is found to be highly rate dependent. At low test rates the crack growth in the reinforced polymers tend to follow a fiber avoidance mode, creating a greater area of new surfaces, which in conjunction with greater degree of interfacial debonding and fiber pullout friction leads to a higher fracture resistance. An increase in loading rate in general results in a more straight and flat crack path, as well as a lesser extent of fiber debonding and pullout. Therefore the fracture toughness is reduced although the frequency of fiber breakage is increased. The fracture behavior of these short fiber reinforced polymers appears to be dictated by the matrix properties when the loading rate is high.     

Heat distortion of phenolic fiber reinforced thermoplastics

Heat distortion temperature of phenolic short fiber-reinforced thermoplastics (FRTP) (polystyrene, polypropylene, nylon 66), which are molded by injection, have been estimated by an ASTM standard and the reinforced effect is examined from the standpoint of the dependence on the fiber content and maximum fiber stress (bending stress). For polystyrene (PS), the temperature dependence on the fiber content and the maximum fiber stress dependence on the gradient (increase in heat distortion temperature with an increase in 1% of fiber) of these lines show a fine relation, and in regard to the heat distortion temperature, also indicates a nearly linear relation on a log–log scale. However, for the other two polymers, a good relation cannot be recognized but shows a nonlinear one. For polypropylene (PP), a decrease in the phenomenon in the heat distortion temperature dependence on fiber content is found and an interpretative explanation of the results is given.     

国外纤维增强热塑性塑料发展概况

纤维增强热塑性塑料（FRTP）因其重量轻,抗冲击性和疲劳韧性好,成型周期短,可循环利用等诸多优点,近年在稳定发展。本文概述了国外纤维增强热塑性塑料的发展形势、材料种类、知名厂商及其产品和FRTP最终制品的成型工艺。     

Effects of processing conditions on the fiber length distribution and mechanical properties of glass fiber reinforced nylon‐6

The effects of processing conditions on fiber length degradation were investigated in order to produce composites with higher performance. Nylon‐6 was compounded with glass fibers in a twin‐screw extruder for various combinations of screw speed and feed rate. Collected samples were injection molded and Izod impact and tensile tests were performed in order to observe the effect of fiber length on the mechanical properties. Also, by using the extruded and injection molded smaples, fiber length distribution curves were obtained for all the experimental runs. Results show that when the shear rate is increased through the alteration of the screw speed and/or the feed rate, the average fiber length decreases. Impact strength, tensile modulus and tensile strength increase, whereas elongation at break decreases with the average fiber length.