Influence of wood fiber size on extrusion foaming of wood fiber/HDPE composites

Foaming of wood fiber/plastic composites (WPC) with a fine‐celled structure can offer benefits such as improved ductility and impact strength, lowered material cost, and lowered weight, which can enhance their utility in many applications. Although a great deal of attention is now being focused on these composites in the scientific literature, there are still numerous aspects of WPC processing that need elucidation. In this context, this article investigates the effects of wood fiber (WF) size on fine‐celled extrusion foaming of WPC in terms of cell size, cell size distribution, and foam density. The effects of WF size and coupling agent content on the viscosity of WPC are also investigated. The experimental results revealed that the small‐sized WF provides a better cell morphology, a smaller cell size, and a better cell uniformity in WPC foams. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Effect of fumed silica nanoparticles on glass fiber filled thermotropic liquid crystalline polymer composites

Glass fiber filled thermotropic liquid crystalline polymer (gLCP)/silica composites were prepared by melt compounding. The total torque of the gLCP/silica composites decreased and the melt flow index increased with increasing silica content, which indicates that the fumed silica nanoparticles act as good processing aids and enhance the processing behavior of gLCP/silica composites. The rheological properties of the gLCP/silica composites were significantly dependent on the silica content. The complex viscosity and storage modulus (G′) of the gLCP/silica composites decreased with increasing silica content. This was attributed to the ability of the silica nanoparticles to break the glass fiber–glass fiber interactions in the gLCPs. The storage modulus and loss modulus (G″) of the gLCP/silica composites increased with increasing frequency, and the increment was more significant at low frequency. Incorporation of a small quantity of silica nanoparticles improved the thermal stability and mechanical properties of gLCP/silica composites. However, at high silica nanoparticle content the mechanical properties of gLCP/silica composites decreased because of the aggregation of silica nanoparticles. POLYM. COMPOS., 2009. © 2008 Society of Plastics Engineers     

Long jute fiber‐reinforced polypropylene composite: Effects of jute fiber bundle and glass fiber hybridization

Two types of long jute fiber pellet consisting of twisted‐jute yarn (LFT‐JF/PP) and untwisted‐jute yarn (UT‐JF/PP) pellets are used to prepare jute fiber–reinforced polypropylene (JF/PP) composites. The mechanical properties of both long fiber composites are compared with that of re‐pelletized pellet (RP‐JF/PP) of LFT‐JF/PP pellet, which is re‐compounded by extrusion compounding. High stiffness and high impact strength of JF/PP composites are as a result of using long fiber. However, the longer fiber bundle consequently affects the distribution of jute fiber. The incorporation of 10 wt % glass fibers is found to improve mechanical properties of JF/PP composites. Increasing mechanical properties of hybrid composites is dependent on the type of JF/PP pellets, which directly affect the fiber length and fiber orientation of glass fiber within hybrid composites. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 41819.     

Mechanical properties of poly(styrene‐co‐acrylonitrile)‐modified epoxy resin/glass fiber composites

Poly(styrene‐co‐acylonitrile) was used to modify diglycedyl ether of bisphenol‐A type epoxy resin cured with diamino diphenyl sulfone and the modified epoxy resin was used as the matrix for fiber‐reinforced composites (FRPs) to get improved mechanical properties. E‐glass fiber was used as fiber reinforcement. The tensile, flexural, and impact properties of the blends and composites were investigated. The blends exhibited considerable improvement in mechanical properties. The scanning electron micrographs of the fractured surfaces of the blends and tensile fractured surfaces of the composites were also analyzed. The micrographs showed the influence of morphology on the properties of blends. Results showed that the mechanical properties of glass FRPs increased gradually upon fiber loading. Predictive models were applied using various equations to compare the mechanical data obtained theoretically and experimentally. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Study on effects of short glass fiber reinforcement on the mechanical and thermal properties of PC/ABS composites

This article mainly investigated the length distributions of the alkali‐free short glass fibers in specimens and their effect on the mechanical and thermal properties of the composites. The results show that the initial length, addition level and feed way of the fibers have obvious effects on the length distributions of fibers in specimens, and thereby the mechanical and thermal properties of the composites. The main‐direction feed way has an intense shear action on the fibers in specimens. With the increase of the fiber content, the reinforcing effect of fibers on the tensile strength, flexural strength and flexural modulus of the composites is increased, while the impact strength is decreased first and then tends to be stable, and the strength factor (F) of the tensile strength to weld line is significantly reduced. The longer the fiber lengths in specimens are, the more obvious the reinforcing and toughening effects are. To some extent, with the increase of the fiber content, the storage modulus (E′) and loss modulus (E′′) of the specimens are increased, but the loss factor (Tan δ) is reduced. The effect of the fiber initial lengths on the heat‐degradation of composites is smaller than that of the fiber content. Meanwhile, adding fibers can improve the thermal stability of the composites, and this law is also confirmed by the heat deflection temperature (HDT) test. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 40697.     

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     

Effects of raw fiber materials,fiber content,and coupling agent content on selected properties of polyethylene/wood fiber composites

This study investigated the effects of raw fiber materials, fiber content, and coupling agent (CA) content on mixing torque, rheological properties, and crystallization behavior of wood plastic composites (WPC). WPCs were prepared through melt molding processes. This study adopted a response surface strategy of 20 run optimal design for three factors including wood fiber type, fiber content, and CA content. Wood fiber type or wood fiber characteristics influence equilibrium torque and viscosity. The power index n for viscosity as a function of frequency was affected not only by wood fiber content, but also by CA content and wood fiber type. Addition of wood fibers to the system as nucleating agents favors polyethylene crystallization. The values of crystallization enthalpy and melt enthalpy were correlated with wood fiber content and CA content, but they were not affected by wood fiber type. The melt temperatures of polyethylene and composites were comparable. This indicates that the crystallite structure and lamellar thickness are similar. POLYM. ENG. SCI., 47:1678–1687, 2007. © 2007 Society of Plastics Engineers     

Mechanical characterization and fractography of glass fiber/polyamide (PA6) composites

The mechanical properties of the glass fiber reinforced Polyamide (PA6) composites made by prepreg tapes and commingled yarns were studied by in‐plane compression, short‐beam shear, and flexural tests. The composites were fabricated with different fiber volume contents (prepregs—47%, 55%, 60%, and commingled—48%, 48%, 49%, respectively) by using vacuum consolidation technique. To evaluate laminate quality in terms of fiber wet‐out at filament level, homogeneity of fiber/matrix distribution, and matrix/fiber bonding standard microscopic methods like optical microscopy and scanning electron microscopy (SEM) were used. Both commingled and prepreg glass fiber/PA6 composites (with V_f ∼ 48%) give mechanical properties such as compression strength (530–570 MPa), inter‐laminar shear strength (70–80 MPa), and transverse strength (80–90 MPa). By increasing small percentage in the fiber content show significant rise in compression strength, slight decrease in the ILSS and transverse strengths, whereas semipreg give very poor properties with the slight increase in fiber content. Overall comparison of mechanical properties indicates commingled glass fiber/PA6 composite shows much better performance compared with prepregs due to uniform distribution of fiber and matrix, better melt‐impregnation while processing, perfect alignment of glass fibers in the composite. This study proves again that the presence of voids and poor interface bonding between matrix/fiber leads to decrease in the mechanical properties. Fractographic characterization of post‐failure surfaces reveals information about the cause and sequence of failure. POLYM. COMPOS., 36:834–853, 2015. © 2014 Society of Plastics Engineers     

Effects of A,B, and S components on fiber length distribution,mechanical, and impact properties of carbon fiber/ABS composites produced by different processing methods

Carbon fiber/ABS composites with different acrylonitrile, butadiene, and styrene components were produced via extrusion/injection and long fiber thermoplastic (LFT)/injection molding processes, respectively. The effect of the components on fiber length distribution, tensile, flexural, impact, and dynamic mechanical properties of the composites was investigated. The properties of carbon fiber/ABS composites produced using 12 mm-long LFT pellets were markedly higher than those produced using extruded pellets made with 12 mm-long chopped carbon fibers. Uses of LFT pellets were preferable to enhancing the mechanical properties of carbon fiber/ABS composites. The tensile, flexural, and dynamic mechanical properties were increased in order of ABS750sw > ABS720 ≥ ABS780 > ABS740, whereas the impact strength was increased in order of ABS740 > ABS780 > ABS720 ≈ ABS750sw. Less carbon fiber damages and less carbon fiber length degradation upon LFT processing resulted in longer fiber length distribution and higher fiber aspect ratio in the composites with LFT pellets, indicating a beneficial reinforcing effect, which was responsible for the increased mechanical properties of ABS composites, particularly with ABS750sw. The results were agreed with each other, significantly depending on the A, B, and S components, being supported by fiber length distribution, fiber aspect ratio, and fracture surfaces.     

Structure and properties of UHMWPE fiber/carbon fiber hybrid composites

Ultrahigh molecular weight polyethylene (UHMWPE) fiber/carbon fiber hybrid composites were prepared by inner‐laminar and interlaminar hybrid way. The mechanical properties, dynamic mechanical analysis (DMA), and morphologies of the composites were investigated and compared with each other. The results show that the hybrid way was the major factor to affect mechanical and thermal properties of hybrid composites. The resultant properties of inner‐laminar hybrid composite were better than that of interlaminar hybrid composite. The bending strength, compressive strength, and interlaminar shear strength of hybrid composites increased with an increase in carbon fiber content. The impact strength of inner‐laminar hybrid composite was the largest (423.3 kJ/m²) for the UHMWPE fiber content at 43 wt % to carbon fiber. The results show that the storage modulus (E′), dissipation factor (tan δ), and loss modulus (E″) of the inner‐laminar hybrid composite shift toward high temperature remarkably. The results also indicate that the high‐performance composite with high strength and heat resistance may be prepared by fibers' hybrid. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 101: 1880–1884, 2006     

Mechanical properties of injection molded long fiber polypropylene composites,Part 2: Impact and fracture toughness

This study describes the effect of fiber length and compatibilizer content on notched izod impact and fracture toughness properties. Long fiber polypropylene (LFPP) pellets of different sizes were prepared by extrusion process using a new radial impregnation die, and subsequently, pellets were injection molded as described in previous publication 1 . The content of glass fiber reinforcement was maintained same for all compositions. Maleic‐anhydride grafted polypropylene (MA‐g‐PP) was chosen as a compatibilizer to increase the adhesion between glass fiber and PP matrix and its content was maintained at 2 wt%. Notched izod impact property was studied for LFPP composites prepared with and without compatibilizer for different pellet sizes. Failure mechanism due to sudden impact was analyzed with scanning electron micrographs and was correlated with impact property of LFPP composites. Fracture and failure behavior of injection molded LFPP composite were studied and relationship between fracture toughness and microstructure of LFPP composite was analyzed. The microstructure of the composites was characterized by the dimensionless reinforcing effectiveness parameter, which accounts for the influence of fiber layer structure, fiber alignment, fiber volume fraction, fiber length distribution, and aspect ratio. Matrix stress condition factor and energy absorption ratio were determined for LFPP composites prepared with and without compatibilizer. Failure mechanism of both the matrix and fiber, revealed with SEM images, were discussed. POLYM. COMPOS., 2008. © 2008 Society of Plastics Engineers     

High performance of bamboo‐based fiber composites from long bamboo fiber bundles and phenolic resins

Lignocellulosic materials can be used for the development of bio‐based composites. This study explores the potential of long bamboo fiber bundles extracted directly from bamboo stems using the novel mechanical method and bamboo‐based fiber composites (BFC) fabricated using long bamboo fiber bundles and phenolic resins via cold pressing and thermal cure process. The microstructure, mechanical properties, and durability of BFC were evaluated, results being compared with raw bamboo and other commercialized bamboo fiber composites. The mechanical properties of BFC reinforced with 87% (w/w) long bamboo fiber bundles increased more than 50% than those of raw bamboo and were significantly higher than those of other bamboo‐based composites. Lower water absorption and thickness swelling were obtained in the case where bamboo fiber bundles with the small fineness. Higher tensile strength was obtained in the case where bamboo fiber bundles with large sizes of bamboo fiber bundles. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 40371.     

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.     

The rheology and extrusion processing performance of wood/melamine composites

A modified melamine resin that exhibits both thermoplastic and thermoset behaviors was used as a matrix for wood plastic composites (WPCs). The thermoplastic melamine (TPM) resin exhibits a glass transition at approximately 34°C and continues to be thermally malleable until a crosslinking reaction develops with additional heating and an acid catalyst. Varying blends of TPM and wood flour were evaluated for their rheology and curing behavior using torque rheometry. WPC composites were manufactured with extrusion methods and final product properties determined. The torque rheometry results showed a highly dependent relationship of the curing behavior to the amount of wood flour utilized and temperature. Based upon the torque rheometry results, two extrusion platforms were developed to initiate the curing process; (1) cure within the die land and (2) post‐cure of the extrudate. The post‐cure procedure provided composites with higher mechanical properties. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 39858.     

Relationship between processing method and microstructural and mechanical properties of poly(ethylene terephthalate)/short glass fiber composites

Composites of recycled poly(ethylene terephthalate) (PET) reinforced with short glass fiber (GF) (0, 20, 30, and 40 wt %) were compounded in a single‐screw extruder (SSE) and in a intermeshing corotating twin‐screw extruder (TSE). An SSE fitted with a barrier double‐flight screw melting section in between two single‐flight sections and a TSE with a typical screw configuration for this purpose were used. The composites were subsequently injection molded at two different mold temperatures (10 and 120°C), with all other operative molding parameters kept constant. The effects of processing conditions on composite microstructure, PET degree of crystallinity, and composite mechanical properties were evaluated. Appropriate dispersive and distributive mixing of the glass fiber throughout the PET matrix as well as fine composite mechanical and thermal‐mechanical properties were achieved regardless of whether the composites were prepared in the SSE or TSE. The performance of the SSE was attributed to the efficiency of the barrier screw melting section in composite mixing. The mold temperature influenced the mechanical properties of the composites, by controlling of the degree of crystallinity of the PET in the composites. For a good balance of mechanical and thermal‐mechanical properties, high mold temperatures are desirable, typically, 120°C for a mold cooling time of 45 s. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci 2008     

Effect of curauá fiber content on the properties of poly(hydroxybutyrate‐co‐valerate) composites

Poly(hydroxybutyrate‐co‐valerate) (PHBV), a biodegradable polymer produced from a renewable microbiological source, was reinforced with varying amounts of curauá fibers (CFs). The composites were produced using a twin‐screw extrusion and injection process. Scanning electron microscopy showed poor adhesion between the matrix and fiber; however, mechanical testing showed that the addition of the fiber improved the mechanical properties. Composites with 20 and 30 wt% CF displayed the best properties; however, because of the difficulties in processing composites with a CF content of 30 wt%, it was concluded that the ideal content of CF was 20 wt%. POLYM. COMPOS., 2013. © 2013 Society of Plastics Engineers     

Density reduction behaviors and cell morphology in extrusion of LLDPE/wood fiber composites with physical and chemical blowing agents

Foamed wood fiber/plastic composites (WPC) with a fine-cell structure offer many benefits compared with the unfoamed WPC, such as the reduced material cost and density, the improved toughness, and the enhanced processability. However, it is extremely challenging to achieve the desired density reduction and obtain a fine-cell structure simultaneously. One of the obstacles is that the volatiles released from the wood fiber (WF) during processing should be suppressed to ensure a fine-cell structure. Linear low-density polyethylene (LLDPE) has a relatively low melting temperature, and it can reduce the processing temperature and suppress volatiles when used as a polymer matrix for foamed WPC. This paper systematically investigates the foamability of LLDPE/WF composites in a continuous foam extrusion, with both a chemical blowing agent and a physical blowing agent (PBA). It turns out that the PBA-based foaming led to a smaller cell size and a narrower cell size distribution. © 2019 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2020 , 137, 48829.     

Pultruded fiber reinforced blocked polyurethane (PU) composites. II. Processing variables and dynamic mechanical properties

Unidirectional fiber reinforced blocked polyurethane (PU) composites have been prepared by the pultrusion process. The effects of processing variables on the mechanical properties and dynamic mechanical properties of fiber reinforced PU composites by pultrusion have been studied. The processing variables investigated included pulling rate (in-line speed), die temperature, postcure time and temperature, and filler type and content. The dynamic mechanical properties of the composites produced by the process were studied utilizing dynamic mechanical spectrometer. Results show that the composites possessed various optimum pulling rates at different die temperatures. From the DSC data analysis, swelling ratio, and mechanical properties, the optimum die temperature was determined. It was found that the mechanical properties increase with filler content for various types of filler. The increasing of mechanical properties depends on the optimum postcure temperature and time. However, the properties decreased for longer postcure times since the composite materials were degraded. The glass-transition temperature (T_g) increased slightly and the damping peak (tan δ) was broadened due to fiber reinforcement. The dynamic mechanical moduli (G′, G″) of pultruded PU composites are apparently higher than those of the matrices. The moduli (G′, G″) increase with increasing fiber and filler content, and the damping peak becomes broad. Effect of postcuring on the degree of crosslinking, T_g, and dynamic modulus will be discussed.     

Mechanical properties of natural fibers/polyamides composites

The aim of this investigation has been to use high performance thermoplastic matrices such as polyamides instead of the commonly used polyolefins to develop natural fiber composites for substituting glass fibers without renouncing to their mechanical properties. For this purpose, different natural fibers such as flax, jute, pure cellulose, and wood pulps have been melt compounded with different polyamides to analyze the effect of fiber content on mechanical properties. Fibers have not been treated as polyamides are less hydrophobic than polyolefins. Thermal behavior of the different fibers was determined by thermogravimetry to know the boundary for processing at high temperatures, since the melting points of the polyamides are much higher than those of polyolefins and this could lead to a higher degradation of the natural fibers. Rheological parameters were deduced by measuring torque values during the mixing process. Flexural and tensile modulus and strength of composites were analyzed, finding an increase in the mechanical properties compared with the unreinforced matrix that turns natural fibers into a considerable reinforcement offering a wealth of possibilities for industrial applications. POLYM. COMPOS., 2009. © 2008 Society of Plastics Engineers     

Processing and properties of solution impregnated carbon fiber reinforced polyethersulfone composites

Carbon fiber reinforced polymer composites are attractive because of their high stiffness and strength‐to‐weight ratios. In order to fully utilize the stiffness and strength of the reinforcement fiber, it is necessary to bring the polymer matrix and the reinforcement fiber together with homogeneous wetting. In this paper, a solution processing technique and the mechanical properties of carbon fiber reinforced polyethersulfone composites were investigated. The polymer was dissolved in cyclopentanone and fed onto a continuous carbon fiber tow using a drum winder. The solution‐processed composite prepregs were then layed up and compression molded into unidirectional composite panels for evaluation. The composite samples showed uniform fiber distribution and reasonably good wetting. The longitudinal flexural modulus was as high as 137 GPa, and longitudinal flexural strength 1400 MPa. In addition, the effects of polymer grade and processing conditions on the mechanical properties of the composites were discussed. It is suggested that the transverse properties and interlaminar fracture toughness could benefit from higher polymer matrix molecular weight. A careful design in the spatial distribution of the molecular weight would be necessary for practical applications.