Resin transfer moulding of anionically polymerised polyamide 12

Liquid composite moulding of Lactam 12 monomer and activating system (APLC12) into satin weave carbon fabrics is investigated, with emphasis on minimising the void content in the final part. The main sources for void formation are identified. The solidification shrinkage is quantified to account for at most 9% in the matrix. Optimal flow conditions are determined to minimize void content during liquid moulding. Finally, as the monomer is kept under Nitrogen prior to processing, diffusion and solubility of Nitrogen in the monomer are characterized, to indicate that Nitrogen coalescence during injection is a major cause of voids in the final part. The average void content is reduced from initially 15% to below 1% in polyamide 12 based composite plates with optimised process conditions.     

Capillary effects on flax fibers – Modification and characterization of the wetting dynamics

Introducing bio-based composites has now become an opportunity of development for industry. Accordingly, Liquid Composite Moulding (LCM) processes are increasingly used for manufacturing those composites, mainly in the transportation industry, since they are considered as effective and low cost routes to manufacture bio-based composites fitting high quality requirements, even for parts with complex shape. However observations of a large amount of voids in bio-based composites call for an improved understanding of the local wetting phenomena that occur during impregnation of the natural reinforcements. The purpose of the present work is to study the influence of flax fiber surface chemistry on the local wetting dynamics. Flax reinforcements were submitted to a thermal treatment to modify the chemical composition of fiber surface. In order to analyze the fiber’s wetting behavior, some methods for measuring apparent static contact angles and surface energy were firstly validated on solids of defined geometry, and subsequently applied to untreated and treated flax fibers. The Owens–Wendt’s approach was used to determine both components of apparent surface energy, indicating polar and dispersive interactions in materials. Subsequently dynamic tests were carried out on both types of chopped flax fibers in order to evaluate apparent advancing dynamic contact angles. Considerations about morphological effects have also been included. Finally bio-based composite plates reinforced with untreated and treated flax quasi-UD were simultaneously fabricated by LCM process, and observation of the porosities highlighted some benefits of using treated flax fibers.     

Heat treated wood–nylon 6 composites

Heat treatment is a relatively benign modification method that is growing as an industrial process to improve hygroscopicity, dimensional stability and biological resistance of lignocellulosic fillers. There also has been increased interest in the use of lignocellulosic fillers in numerous automotive applications. This study investigated the influence of untreated and heat treated wood fillers on the mechanical and rheological properties of wood filled nylon 6 composites for possible under-the-hood applications in the automobile industry where conditions are too severe for commodity plastics to withstand. In this study, exposure of wood to high temperatures (212 °C for 8 h) improved the thermal stability and crystallinity of wood. Heat treated pine and maple filled nylon 6 composites (at 20 wt.% loading) had higher tensile strengths among all formulations and increased tensile strength by 109% and 106% compared to neat nylon 6, respectively. Flexural modulus of elasticity (FMOE) of the neat nylon 6 was 2.34 GPa. The FMOE increased by 101% and 82% with the addition of 30 wt.% heat treated pine and 20 wt.% heat treated maple, where it reached maximum values of 4.71 GPa and 4.27 GPa, respectively. The rheological properties of the composites correlated with the crystallinity of wood fillers after the heat treatment. Wood fillers with high crystallinity after heat treatment contributed to a higher storage modulus, complex viscosity and steady shear viscosity and low loss factor in the composites. This result suggests that heat treatment substantially affects the mechanical and rheological properties of wood filled nylon 6 composites. The mechanical properties and thermogravimetric analysis indicated that the heat treated wood did not show significant thermal degradation under 250 °C, suggesting that the wood-filled nylon composites could be especially relevant in thermally challenging areas such as the manufacture of under-the-hood automobile components.     

Mechanical characterisation of carbon fibre–PEEK manufactured by laser-assisted automated-tape-placement and autoclave

Obtaining autoclave-level mechanical properties using in-situ consolidation of thermoplastic composites by Automated Tape Placement (ATP) is challenging. However, relatively recent availability of high quality ATP grade pre-preg material and tape heads equipped with more efficient heat sources (e.g. lasers) offers an opportunity to achieve improved mechanical properties and deposition rates. In the present study, carbon fibre–PEEK laminates, manufactured by laser-assisted ATP (LATP) and autoclave, are compared. Analysis of the through-thickness temperature distribution during LATP processing using thermocouples indicates that LATP cooling rates are extremely rapid and suggests full through-thickness melting of the pre-preg tape may not occur. Inadequate crystallinity, in conjunction with voids, compromised mechanical properties compared to autoclaved laminates but was beneficial in terms of the toughness of LATP laminates. Optimisation of pre-preg properties and processing parameters is required to realise the full potential of the LATP process in terms of mechanical properties, energy requirements, cost and deposition rates.     

Effect of carbon black nanoparticle intrinsic properties on the self-monitoring performance of glass fibre reinforced composite rods

Self-monitoring composite rods, made of an internal conductive core surrounded by an external structural skin, were manufactured and tested. Both parts were made of glass fibre-epoxy. Electrical conductivity was achieved in the inner core by incorporating as an alternative high surface area or low surface area carbon black in the resin. Self-monitoring performance was assessed by simultaneous mechanical and electrical resistance measurements. The aim was to correlate the electrical resistance variation to stress. Only one type of material showed appropriate self-monitoring properties, since increase of electrical resistance was recorded at increasing loading (both monothonic and cyclic tensile loading), while electrical resistance recovery at high loads was found in the other case. Calorimetric analysis, rheological measurements and SEM observations were carried out to explain this result. Filler dispersion seems to be the key feature affecting the self-monitoring properties. Only high surface area nanoparticles can ensure self-monitoring reliability.