Production of continuous fiber thermoplastic composites by in-situ pultrusion

Epple, Stefan; Bonten, Christian

doi:10.1063/1.4873820

Cited by 14 publications

(10 citation statements)

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“…Luisier et al developed a pilot reactive injection pultrusion line in the base of anionic polymerization of polyamide-12 (PA-12) [16]. Epple et al successfully prepared thermoplastic composites with anionic PA-6 using a pultrusion process, but the optimization of process condition, properties, and microstructure of pultruded composites were not reported in detail [17].…”

Section: Introductionmentioning

confidence: 99%

Thermoplastic Reaction Injection Pultrusion for Continuous Glass Fiber-Reinforced Polyamide-6 Composites

et al. 2019

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In this paper, glass fiber-reinforced polyamide-6 (PA-6) composites with up to 70 wt% fiber contents were successfully manufactured using a pultrusion process, utilizing the anionic polymerization of caprolactam (a monomer of PA-6). A novel thermoplastic reaction injection pultrusion test line was developed with a specifically designed injection chamber to achieve complete impregnation of fiber bundles and high speed pultrusion. Process parameters like temperature of injection chamber, temperature of pultrusion die, and pultrusion speed were studied and optimized. The effects of die temperature on the crystallinity, melting point, and mechanical properties of the pultruded composites were also evaluated. The pultruded composites exhibited the highest flexural strength and flexural modulus, reaching 1061 MPa and 38,384 MPa, respectively. Then, effects of fiber contents on the density, heat distortion temperature, and mechanical properties of the composites were analyzed. The scanning electron microscope analysis showed the great interfacial adhesion between fibers and matrix at 180 °C, which greatly improved the mechanical properties of the composites. The thermoplastic reaction injection pultrusion in this paper provided an alternative for the preparation of thermoplastic composites with high fiber content.

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Section: Introductionmentioning

confidence: 99%

Thermoplastic Reaction Injection Pultrusion for Continuous Glass Fiber-Reinforced Polyamide-6 Composites

et al. 2019

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“…The main difference between the reactive and nonreactive pultrusion processes is the design of the heated die block. In the reactive pultrusion process, preheated unimpregnated fiber is fed into the heated die block where fiber impregnation and polymerization of matrix take place (in situ polymerization), and the polymerized matrix has properties of thermoplastic melt [ 40 ]. The following polymers are typically used in the RIM pultrusion: polycarbonates (PC), polyesters (PE), polyurethanes (PU), polymethylmethacrylates (PMMA), and polyamides (PA) (in particular, PA-6 synthesized from ε-caprolactam (ε-CL) monomer) [ 138 ].…”

Section: Thermoplastic Pultrusion and Process Parametersmentioning

confidence: 99%

“…Fiber reinforcement is impregnated by hot melt thermoplastic polymer; then, after cooling, the part is ready for use. Compared to thermosetting composites, thermoplastic composites have higher impact toughness [ 33 , 34 , 35 , 36 ], are faster to produce [ 37 , 38 ], have higher service temperatures [ 39 ], can be joined by welding [ 40 , 41 , 42 , 43 ], have less environmental impact [ 44 , 45 , 46 ], and can be recycled [ 47 , 48 , 49 , 50 ]; their source materials have virtually unlimited shelf life [ 51 , 52 , 53 , 54 , 55 , 56 , 57 ]. Pultruded thermoplastic profiles are used in various structures and sectors, such as vehicles [ 58 , 59 , 60 , 61 , 62 , 63 ] and aircrafts construction [ 64 , 65 , 66 ], aerospace [ 67 , 68 , 69 ] and civil engineering [ 70 , 71 , 72 , 73 ], energy systems [ 74 ], restoration of deteriorated structures [ 75 ], marine applications [ 76 , 77 , 78 , 79 ], oil and gas industries [ 80…”

Section: Introductionmentioning

confidence: 99%

Thermoplastic Pultrusion: A Review

et al. 2021

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Pultrusion is one of the most efficient methods of producing polymer composite structures with a constant cross-section. Pultruded profiles are widely used in bridge construction, transportation industry, energy sector, and civil and architectural engineering. However, in spite of the many advantages thermoplastic composites have over the thermoset ones, the thermoplastic pultrusion market demonstrates significantly lower production volumes as compared to those of the thermoset one. Examining the thermoplastic pultrusion processes, raw materials, mechanical properties of thermoplastic composites, process simulation techniques, patents, and applications of thermoplastic pultrusion, this overview aims to analyze the existing gap between thermoset and thermoplastic pultrusions in order to promote the development of the latter one. Therefore, observing thermoplastic pultrusion from a new perspective, we intend to identify current shortcomings and issues, and to propose future research and application directions.

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“…Finally, in all the listed techniques, thermoset resin is commonly used as the matrix material due to its ease of flow and fiber impregnation compared to thermoplastic resin, which has the advantage of better impact resistance, weldability, and recyclability. 2 Additive manufacturing (AM), commonly known as 3-D printing, offers a new approach to fabricate complex parts without the use of expensive complex molds or heavy machinery. 3 Starting with a CAD model of the part, thin (fraction of millimeter thick) slices are extracted by a slicing software and a tool path is generated to create each slice (layer).…”

Section: Introductionmentioning

confidence: 99%

Fracture toughness enhancement of carbon fiber–reinforced polymer composites utilizing additive manufacturing fabrication

Akasheh

Aglan

2018

Journal of Elastomers & Plastics

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The present work reports a novel approach to enhance the fracture resistance and notch sensitivity of carbon fiber-reinforced polymer composites utilizing additive manufacturing (3-D printing) fabrication. The 3-D printed composites utilize carbon fiber bundles to reinforce nylon/chopped fiber resin in a multilayered structure configuration. Single-edge (60°) notched samples were printed using Mark Two printer. Three reinforcement schemes were designed and used to manufacture the specimens. The focus was placed on selective reinforcement at the crack tip to arrest crack initiation. The mechanical properties, fracture toughness, and fracture behavior of the printed composites were evaluated. It was found that wrapping fiber around the notch effectively blunted the notch and redirected crack propagation away from the notch tip, thereby lengthening the crack path and leading to improved fracture resistance. It was also found that such improvement reaches a saturation level. Excessive notch reinforcement beyond optimal limit can reverse the gains in fracture resistance due to notch-targeted reinforcement. Examination of the fracture surface morphology of the printed composites reveals lack of fusion of the sizing of the individual continuous carbon fiber bundles and the lack of adhesion between the matrix layers (nylon/chopped fiber resin) and the adjacent carbon fiber bundle reinforcement. Damage to the fibers within the carbon bundle was also observed. Thus, a synergetic effect of the carbon fiber bundles reinforcement and the matrix requires more optimization to manufacture carbon-reinforced polymer composites using 3-D printing.

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Production of continuous fiber thermoplastic composites by in-situ pultrusion

Cited by 14 publications

References 0 publications

Thermoplastic Reaction Injection Pultrusion for Continuous Glass Fiber-Reinforced Polyamide-6 Composites

Thermoplastic Reaction Injection Pultrusion for Continuous Glass Fiber-Reinforced Polyamide-6 Composites

Thermoplastic Pultrusion: A Review

Fracture toughness enhancement of carbon fiber–reinforced polymer composites utilizing additive manufacturing fabrication

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