Recycled Carbon Fibers in Complex Structural Parts - Organic Sheets Made of rCF Staple Fiber Yarns

Goergen, Christian; Baz, Stephan; Mitscháng, Peter; Gresser, Götz T.

doi:10.4028/www.scientific.net/kem.742.602

Cited by 16 publications

(13 citation statements)

References 1 publication

(1 reference statement)

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“…[30][31][32][33][34] Staple fiber organic sheets made of rCF have been developed based on rCF yarns, providing comparable but not yet equal material properties as virgin CF organic sheets. 35 In Longana et al, 36 the high performance discontinuous fiber process was applied in order to align rCF for the production of epoxy-based prepregs which also provide close to vCF values in terms of mechanical performance. By considering a second recycling loop, values significantly decreased by $20%.…”

Section: State Of the Art: Recycling Of Cfsmentioning

confidence: 99%

Development and validation of recycled carbon fiber-based binder tapes for automated tape laying processes

Rimmel

May

Goergen

et al. 2018

Journal of Composite Materials

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The current growth in use of fiber reinforced polymer composites causes a strongly increasing amount of waste. Current approaches for fiber reinforced polymer composites recycling usually not exploit the potential of endless fibers as they are shortened during recycling and will not be properly aligned in the final product. Considering this, the present work aimed at the development of a recycling process for long recycled carbon fibers, where fiber length is preserved and load-related fiber orientation is possible. The starting point for the presented work was so-called slivers, which are long bundles of fibers resulting from a carding process that has been applied to fiber scrap. The main focus of this work was on the development of a binder mesh application rig that processes the sliver to a binder tape, processable in an automated tape laying process, which in turn required modifications to adapt to the novel tape. The functionality of the binder tape manufacturing process was validated with long recycled carbon fibers slivers with linear density of 4 g/m and fiber lengths between 70 and 120 mm. With the binder tape preform manufactured this way, two alternative routes for composite manufacturing were tested. First, the amount of binder was set so high that direct thermoplastic pressing of the preforms was possible. Second, the amount of binder was minimized, and the preforms were infiltrated with a thermoset resin system via resin transfer molding. While the thermoplastic route showed very deficient fiber–matrix adhesion, with the thermoset route, ≈68% of stiffness and ≈31% of strength of virgin fiber-based composites could be achieved in fiber direction in a unidirectional lay-up.

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Section: State Of the Art: Recycling Of Cfsmentioning

confidence: 99%

Development and validation of recycled carbon fiber-based binder tapes for automated tape laying processes

Rimmel

May

Goergen

et al. 2018

Journal of Composite Materials

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“…The hybrid yarns find their applications as woven fabrics, 34 knitted fabrics 35 and organic sheets 36 for thermoplastic composites as well as heating elements in lightweight applications. 37 So far, the development of hybrid yarn structures consisting of discontinuous CF and thermoplastic fibres has been explored based on wrap spinning , 36,[38][39][40][41] roving frame [42][43][44][45] and DREF-3000 friction spinning [46][47][48] machines. The pioneer work on the use of reclaimed CF to manufacture hybrid yarns by wrap spinning reported by Akonda et al [38][39] showed that the tensile strength of composites manufactured from waste CF fabric prepregs was found to be very low (maximum 160 MPa).…”

Section: Introductionmentioning

confidence: 99%

Mechanical properties of composites manufactured from low twist hybrid yarns made of discontinuous carbon and polyamide 6 fibres

Abdkader

Hasan

Bachor

et al. 2022

Journal of Thermoplastic Composite Materials

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Composites based on e.g. randomly oriented nonwovens and injection moulded structures from discontinuous carbon fibre (CF), which are processed industrially exhibit low tensile strengths of 200–300 MPa and 400 MPa, respectively. In contrast, composites based on twisted hybrid yarns from discontinuous CF and thermoplastic fibre show higher tensile strengths such as 1150 MPa. Reasons are improved fibre orientation and higher fibre volume content. However, tensile strength is still lower than that of uni-directional carbon fibre reinforced composites (CFRP) based on continuous filament yarn, which is around 1560 MPa. The reason is a low fibre orientation due to yarn twisting and high fibre shortening, which occurs throughout the yarn manufacturing process. As mechanical properties of composites largely depend on fibre orientation and length, there is a high potential to achieve higher mechanical properties in CFRP by ensuring gentle processing of CF and reducing yarn twist. However, due to brittleness and smooth surface of CF, spinning of yarns with low twist (<60 T/m (twist per meter)) is challenging. In order to exhaust the potential of hybrid yarns, a semi-industrial process chain to produce hybrid yarns while ensuring gentle processing of discontinuous CF (fibre length 100 mm) and polyamide 6 fibres (fibre length 80 mm) at significantly low level of twist 20 T/m is reported in this paper. Carbon fibre reinforced composite manufactured from these hybrid yarns show high tensile strength (1453 ± 27 MPa), Young’s modulus (94 ± 6 GPa), flexural strength (1090 ± 41 MPa) and flexural modulus (98 ± 5 GPa).

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“…Current research is concentrating on recycling routes with aligned rCF, such as manufacturing of aligned mats, wovens, and noncrimp fabrics (NCF) for organic sheets. 12,21,[32][33][34][35][36][37][38] Recycling of CFs for high-performance materials is strongly in focus. The aim of this article is to introduce CFs as long and as aligned as possible into new structures.…”

Section: Introductionmentioning

confidence: 99%

“…This fact is taken into consideration in current research projects. 18,20,21,[40][41][42][43] In addition to developments on rCF yarns, efforts are also being made to process the fibers into oriented slivers and tapes. [44][45][46] Pickering et al, 7 Allen, 8 Turner et al, 9 Palmer et al, 10 Hofmann et al, 11 and Pickering et al 12 Low to medium Low to medium Automotive semistructures, equipment housings, and aircraft interiors Compression molding of aligned nonwovens, veils, and mats Geiger, 13 Turner et al, 14 Howarth et al, 15 Wong et al, 16 and Pickering et al 17 Medium Medium Automotive noncritical structures, aircraft interiors, and wind turbine noncritical structures Compression molding of wovens, NCF Hengstermann et al, 18,19 Abdkader et al, 20 and Goergen et al 21 Medium to high Medium to high Automotive structures NCF: non-crimp fabrics; rCF: recycled carbon fiber.…”

Section: Introductionmentioning

confidence: 99%

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Deep drawing of organic sheets made of hybrid recycled carbon and thermoplastic polyamide 6 staple fiber yarns

Goergen

Schommer

Duhovic

et al. 2018

Journal of Thermoplastic Composite Materials

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Fully impregnated fiber-reinforced thermoplastic sheets, or the so-called organic sheets, allow the thermoforming of parts within very short cycle times. This article describes the development of the next generation of organic sheet materials based on recycled carbon fibers and polyamide 6 staple fiber yarns. Regardless of the recycled nature of the fibers and an average fiber length of 25 mm, the organic sheets still reach a comparable level of the tensile strength and modulus of continuous fiber-reinforced organic sheets made of virgin CF with the same reinforcement structure. Due to the staple fiber yarn architecture, the organic sheets feature a deep-drawing ability of a total plastic deformation up to 50% in the fiber direction. The effect is enabled via an interfiber sliding when the organic sheet is processed in the molten condition. The creation of a finite element model for the thermoforming process simulation of the material is also presented. Predictions of the plastic strain distribution and its magnitude are shown to agree well with forming experiments where a curved geometry is formed to different depths.

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Recycled Carbon Fibers in Complex Structural Parts - Organic Sheets Made of rCF Staple Fiber Yarns

Cited by 16 publications

References 1 publication

Development and validation of recycled carbon fiber-based binder tapes for automated tape laying processes

Development and validation of recycled carbon fiber-based binder tapes for automated tape laying processes

Mechanical properties of composites manufactured from low twist hybrid yarns made of discontinuous carbon and polyamide 6 fibres

Deep drawing of organic sheets made of hybrid recycled carbon and thermoplastic polyamide 6 staple fiber yarns

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