Thermoplastic Composites 1

Polymer Engineering Polymer Engineering

(MM3POE) (MM3POE)
http://www.nottingham.ac.uk/~eazacl/MM3POE
THERMOPLASTIC THERMOPLASTIC
COMPOSITES COMPOSITES
Thermoplastic Composites 2
Contents
Contents
Introduction
Short Fibre Materials
Properties
Manufacturing processes
Applications
Long Fibre Materials
Properties
Manufacturing processes
Applications
Thermoplastic Composites 3
COMPONENT
1. Introduction 1. Introduction
THERMOPLASTIC
POLYMERS
MATRIX
Prepreg sheet
Commingled yarn/fabric
GMT
sheet
SEMI
FINISHED
Pellets/
Granules
Platelets/
Short fibre
Glass mat
Continuous
fibre
REINF-
ORCEMENT
Thermoplastic Composites 4
2. Short Fibre Reinforced 2. Short Fibre Reinforced
Thermoplastics ( Thermoplastics (SFRTPs SFRTPs) )
Most TP resins can be combined with fibres/fillers to
enhance properties for injection moulding/ extrusion
eg. stiffness, strength, impact, heat distortion
thermal expansion, friction & wear
Reinforcement comes in two
forms - fibrous & mineral:
l
d
Aspect ratio,
a = l/d
Thermoplastic Composites 5
2. 2. SFRTPs SFRTPs
Fibrous reinforcement (eg. glass, carbon, Kevlar):
Improved mechanical & thermal properties
Higher cost & processing difficulties
Anisotropic & non-uniform material properties
Mineral reinforcement (eg. mica, clay):
Enhanced performance
eg. mech. props, dimensional stability
Often at lower cost BUT similar processing difficulties
Moulding compounds supplied as pellets pellets in two
forms:
Thermoplastic Composites 6
2.1 Glass reinforced thermoplastics 2.1 Glass reinforced thermoplastics
Material Density
Kg/m
3
Tensile
Strength
MPa
Flexural
Modulus
GPa
Impact
Strength
kJ/m
2
HDT
o
C
Thermal
Expansion
10
6
/ K
ABS 30% glass 1280
(+230)
100
(+59)
7.6
(+5.4)
1.4
(-3.0)
104
(+13)
16
(-37)
Acetal 30% glass 1630
(+210)
134
(+73)
9.7
(+6.9)
1.8
(+0.5)
163
(+53)
22
(-23)
PC 30% glass 1430
(+230)
128
(+66)
8.3
(+6.0)
3.7
(+1.0)
149
(+20)
13
(-24)
PBT 30% glass 1520
(+210)
134
(+75)
9.7
(+7.4)
2.5
(+1.3)
221
(+167)
12
(-41)
HDPE 30% glass 1170
(+220)
69
(+51)
6.2
(+4.8)
1.1
(+0.7)
127
(+88)
27
(-33)
PP 30% glass 1120
(+210)
67
(+43)
3.8
(+2.6)
3.0
(+2.6)
146
(+89)
20
(-20)
PS 30% glass 1280
(+210)
93
(+45)
9.0
(+5.9)
1.0
(+0.55)
102
(+20)
19
(-17)
Table 1: Mechanical and thermal properties of SFRTPs
Thermoplastic Composites 7
2.1 Glass reinforced thermoplastics 2.1 Glass reinforced thermoplastics
0
1
2
3
4
5
6
7
8
9
10
F
l
e
x
u
r
a
l
M
o
d
u
l
u
s
(
G
P
a
)
ABS Acetal PC PBT HDPE PP PS
Flexural Moduli of SFRTPs
30% glass Base resin
0
20
40
60
80
100
120
140
T
e
n
s
i
l
e
S
t
r
e
n
g
t
h
(
M
P
a
)
ABS Acetal PC PBT HDPE PP PS
Tensile Strength of SFRTPs
30% glass Base resin
Thermoplastic Composites 8
2.1 Glass reinforced thermoplastics 2.1 Glass reinforced thermoplastics
Creep at 40 C for PA 66 (10MPa load)
Data from Bayer AG Durethan Range
0
20
40
60
80
100
120
1 10 100 1000 10000
Time (hours)
%
S
h
o
r
t
t
e
r
m
m
o
d
u
l
u
s
35% glass
0% glass
Thermoplastic Composites 9
2.2 2.2- -2.3 Carbon/ 2.3 Carbon/Aramid Aramid/Long Fibre /Long Fibre
Table 1: Mechanical and thermal properties of SFRTPs (contd)
Material Density
Kg/m
3
Tensile
Strength
MPa
Flexural
Modulus
GPa
Impact
Strength
kJ/m
2
HDT
o
C
Thermal
Expansion
10
6
/ K
PEK30% glass 1530
(+230)
170
(+65)
9.0
(+5.3)
9.0
(+2.0)
358
(+172)
-
PEK30% carbon 1420
(+120)
225
(+120)
17.9
(+14.6)
8.0
(+1.0)
360
(+17.4)
-
PEEK30% glass 1490
(+170)
157
(+65)
10.3
(+6.7)
10.0
(+2.0)
315
(+155)
-
PEEK30% carbon 1440
(+120)
208
(+116)
13.0
(+9.4)
9.0
(+1.0)
315
(+155)
-
PES 30% glass 1600
(+230)
140
(+56)
8.4
(+5.8)
9.0
(+1.0)
216
(+13)
-
Nylon 66
33% glass
1390
(+250)
180d/115c
(+95/+55)
8.7d/5.5c
(+5.8/+4.4)
9d/12c
(+3/-10)
245
(+145)
-
Nylon 66
50% glass
1570
(+430)
200d/155c
(+115/+95)
12d/9.6c
(+9.1/+8.5)
11d/13c
(+5/-9)
250
(+150)
-
Nylon 66 (Verton)
50% glass
1570
(+430)
230d/165c
(+145/+105)
15.8d/11.2c
(+12.9/+10.1)
27d/37c
(+21/+15)
261
(+161)
-
Thermoplastic Composites 10
2.4 Mechanical properties of 2.4 Mechanical properties of SFRTPs SFRTPs
Mechanical properties of SFRTPs depend on:
Fibre length (aspect ratio)
Fibre volume fraction
Fibre orientation

Thermoplastic Composites 11
2.4 Mechanical properties of 2.4 Mechanical properties of SFRTPs SFRTPs
If fibres are parallel to loading, then:
where
V
f
= fibre volume fraction
E
f
, E
m
= fibre & matrix (polymer) moduli
m f f f
E V E V E ) 1 (
1 max
+ =q
The correction factor,
1
, is given by:
(

=
na
na) tanh(
1
1
q
where a = aspect ratio and n depends on fibre distribution and
fibre & polymer properties:
) / 2 ln(
2
d R E
G
n
f
m
=
=
E (short)
E (contin.)
Thermoplastic Composites 12
2.4 Mechanical properties of 2.4 Mechanical properties of SFRTPs SFRTPs
Fibre Length Correction Factor
Glass/Nylon, 30% Vf
0.0
0.2
0.4
0.6
0.8
1.0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Fibre Length (mm)
C
o
r
r
e
c
t
i
o
n
F
a
c
t
o
r
n = 0.208
d = 22 m
(

=
na
na) tanh(
1
1
q
) / 2 ln(
2
d R E
G
n
f
m
=
a = 100
Thermoplastic Composites 13
2.4 Mechanical properties of 2.4 Mechanical properties of SFRTPs SFRTPs
Thermoplastic Composites 14
2.4 Mechanical properties of 2.4 Mechanical properties of SFRTPs SFRTPs
If fibres are parallel to loading,
then:
m f f f
E V E V E ) 1 (
1 max
+ =q
In reality fibres are NOT parallel
to loading, so that:
2D random
3D random
E ~
8
3
E
max
E ~
5
1
E
max
Thermoplastic Composites 15
2.5 Processing of 2.5 Processing of SFRTPs SFRTPs
INJECTION MOULDING INJECTION MOULDING is by far the most important process
In comparison to base polymers, SFRTPs can lead to:
Increased wear on moulding equipment
Anisotropic material properties
Higher melt viscosity
Thermoplastic Composites 16
2.5 Processing of 2.5 Processing of SFRTPs SFRTPs
Viscosity at 25 s
-1
for PA 66
Data from Bayer AG Durethan Range
0
100
200
300
400
500
600
700
800
0 5 10 15 20 25 30 35
Glass fibre content (%mass)
V
i
s
c
o
s
i
t
y
(
P
a
s
)
180
o
C
200
o
C
Thermoplastic Composites 17
2.6 Applications of 2.6 Applications of SFRTPs SFRTPs
General Motors' Vortec 4200 Inline six-cylinder engine features a
robust air intake manifoldmade by Montaplast of North America,
Inc. using DuPont Zytel glass-reinforced nylon
http://www.dupont.com/
AIR-INTAKE SYSTEMS
Compared to metal manifolds:
Metal - machining after casting
Surfaces rougher than composites
Lower mass of composite (up to 50%)
Lower thermal conductivity, so faster
warm-up & reduced emissions
Composite manifolds offer ~ 3%
add. power due to improved air flow
Manufacture of hollow parts:
Lost-core technique
or
2 part, vibration welding
Thermoplastic Composites 18
2.6 Applications of 2.6 Applications of SFRTPs SFRTPs
Carbon/nylon 66 injection
moulded mountain bike wheel
http://www.lnp.com
Verton glass/pp door module
for Mazda 6
http://www.lnp.com
Thermoplastic Composites 19
2.6 Applications of 2.6 Applications of SFRTPs SFRTPs
Carbon/PEEK pump impellor
Glass/PEEK rocket ignitor
Thermoplastic Composites 20
3. Long/Continuous Fibre 3. Long/Continuous Fibre Reinf Reinf. .
Thermoplastics ( Thermoplastics (LFRTPs LFRTPs) )
For medium/high performance, long fibres are needed for
required mechanical properties
Long/continuous fibre thermoplastics thermoplastics have been developed
as alternatives to thermosets thermosets
Disadvantages of thermosets
Matrix brittleness
Ingress by solvents
Limited shelf life
Slow curing cycle
Advantages of thermoplastics
Toughness
Resistance to chemicals
Unlimited shelf life
High volume production
Recycling of scrap
Repair of damaged structures
Disadvantages of thermoplastics
High viscosity
High temperature processing
Thermoplastic Composites 21
3.1 3.1 GMTs GMTs and and LFTs LFTs
Glass Mat Thermoplastic (GMT) random fibre (chopped/
continuous swirl) mat melt impregnated with thermoplastic resin
Material Density
Kg/m
3
Tensile
Strength
MPa
Flexural
Modulus
GPa
Impact
Strength
kJ/m
2
HDT
o
C
Thermal
Expansion
10
6
/ K
C100 F23
M
f
23%chopped fibre
1060 60 3.0 - 145 30-40
B100 F30
M
f
30%chopped fibre
1130 67 4.3 70 150 20-30
B100 F40
M
f
38%chopped fibre
1200 100 5.2 51 155 15-25
G100 F40 M
f
40%
continuous fibre
1220 75 5.8 64 155 25-28
C100 UD45 M
f
23%
chopped/22% UD
1280 270/46 9.6/4.5 201 - 15-25/40-50
Table 2: Properties of Quadrant Plastic Composites glass/PP GMTs
PP 900 25 1 <1 50 100
Thermoplastic Composites 22
3.1 3.1 GMTs GMTs and and LFTs LFTs
Direct Long-Fibre Thermoplastic (LFT-D) fibre (glass) strands
and polymer combined & extruded directly to produce an
alternative to GMT
http://www.ptonline.com
Thermoplastic Composites 23
3.1 3.1 GMTs GMTs and and LFTs LFTs - - Applications Applications
VEHICLE FRONT ENDS
Fatigue (70 million cycles)
Dynamic loading up to 100
o
C
Attachment pts (moulded inserts)
Parts integration
Cost & weight reductions
VW Golf front end - GMT
3.7kg (35% lighter than Steel)
Thermoplastic Composites 24
3.1 3.1 GMTs GMTs and and LFTs LFTs - - Applications Applications
SEAT STRUCTURES
Strength, stiffness & toughness
Parts integration, moulded inserts
Rear impact protection
Audi TT rear seat back
3.5 Kg incl steel frame & carpet
Integral seat belt support
www.quadrantplastics.com
Thermoplastic Composites 25
3.1 3.1 GMTs GMTs and and LFTs LFTs - - Applications Applications
BATTERY TRAYS
Support battery weight
Chemical resistance (battery acid)
BMW battery tray
<1 Kg incl. integral inserts
Dimensional stability (-30 to +80 C)
www.quadrantplastics.com
Thermoplastic Composites 26
3.2 Continuous Fibre Reinforced 3.2 Continuous Fibre Reinforced TPs TPs
Best mechanical properties are achieved with CONTINUOUS CONTINUOUS
FIBRES FIBRES (ideally aligned)
UD tapes & laminates
Woven fabrics
Thermoplastic matrices can be combined with aligned fibres by:
Film stacking
Hybrid (commingled) yarns
Powder impregnation
Also: polymerisation control (eg. APC APC- -2 2)
Thermoplastic Composites 27
3.2 Continuous Fibre Reinforced 3.2 Continuous Fibre Reinforced TPs TPs
Material Density
Kg/m
3
Tensile
Strength
MPa
Flexural
Modulus
GPa
Impact
Strength
kJ/m
2
HDT
o
C
Thermal
Expansion
10
6
/ K
Twintex 1/1
V
f
35% glass/PP
1500 300 13 180 159 13
Plytron 1/1
V
f
35% glass/PP
1480 360 17 - 156 20
Twintex 1/1
V
f
50% glass/PET
1950 440 23 205 257 15
Plytron UD
V
f
35% glass/PP
1480 720/11 21/- 383 156 7
Twintex UD
V
f
50% glass/PP
1750 700/- 32/- 330 159 -
TEPEX 101 1/1
V
f
47% glass/PA66
1800 380 22 - 255 15
CETEX 7781 1/1
V
f
50% glass/PEI
1910 465 26 - 200
service temp
-
TEPEX 201 1/1
V
f
48% carbon/PA66
1500 755 44 - 255 -
CETEX T300 1/1
V
f
50% carbon/PEI
1510 665 47 - 200
service temp
-
Schappe Techs. 1/1
V
f
56% carbon/PA12
1440 801 52 - - -
SUPreMIM7 UD
V
f
60% carbon/PEEK
1600 2400/68 120/- - 250
service temp
-
Cytec APC-2 UD
V
f
63% carbon/PEEK
1600 2400/82 138/- - 250
service temp
-
Table 3: Properties of aligned fibre composites
Thermoplastic Composites 28
3.2 Continuous Fibre Reinforced 3.2 Continuous Fibre Reinforced TPs TPs
VT Halmatic 6.7m rigid inflatable boat
Vacuum formed using woven glass/pp Twintex
www.twintex.com
Peugeot 806 bumper -
woven glass/pp Twintex
combined with GMT
www.twintex.com
Thermoplastic Composites 29
3.2 Continuous Fibre Reinforced 3.2 Continuous Fibre Reinforced TPs TPs
APC-2 Williams Formula 1 gear selector
APC-2 Apache helicopter horizontal stabiliser
Thermoplastic Composites 30
3.2 Continuous Fibre Reinforced 3.2 Continuous Fibre Reinforced TPs TPs
Airbus A380
www.airbus.com
Glass/PPS wing fixed leading edge (J-nose)
Stork Fokker
Thermoplastic Composites 31
3.3 Mechanical properties of 3.3 Mechanical properties of LFRTPs LFRTPs
0
10
20
30
40
50
60
70
0 20 40 60 80 100
Fibre Volume Fraction (%)
L
o
n
g
i
t
u
d
i
n
a
l
M
o
d
u
l
u
s
(
G
P
a
)
UD
0/90
0/+-45/90
+/-45
2D Random
m f f f
E V E V E ) 1 (
0 1
+ =q

=
i i
a o q
4
0
cos
Thermoplastic Composites 32
3.4 Processing of 3.4 Processing of LFRTPs LFRTPs
Industrial hot flow compression moulding facility for GMT/LFT
Thermoplastic Composites 33
3.4 Processing of 3.4 Processing of LFRTPs LFRTPs
Compression moulding simulation for automotive front end
http://www.m-base.de/main/express.html
Thermoplastic Composites 34
3.4 Processing of 3.4 Processing of LFRTPs LFRTPs
Vacuum consolidation for commingled thermoplastic composites
(www.twintex.com)
Sealant
Release film
Vacuum
Connector
Vacuum bag
Tool
Twintex
Bleeder
Frame
Sealant
Release film
Vacuum
Connector
Vacuum bag
Tool
Twintex
Bleeder
Frame
Thermoplastic Composites 35
3.4 Processing of 3.4 Processing of LFRTPs LFRTPs
formed part
rapid
transfer
device
infra-red oven
control
pyrometers
emitters
reflectors
transfer
frame
heated
composite
shaped
rubber tool
moving bolster
blank holder
to apply
membrane
stresses
rigid lower tool
fast acting hydraulic press
textile sheet
for forming
accumulators
Matched mould forming for aligned thermoplastic composites
(M.D. Wakeman- Fig. 6.15 in Design & Manufacture of Textile Composites, ed.
A C Long, Woodhead Publishing Ltd 2005)
Thermoplastic Composites 36
4. Summary 4. Summary
0.01
0.1
1
10
1 10 100
Specific Stiffness (MNm/kg)
S
p
e
c
i
f
i
c
S
t
r
e
n
g
t
h
(
M
N
m
/
k
g
)
PP
PA66
GMT/LFT
PA66/glass
SFRTP
PEEK/carbon
SFRTP
Twintex/
Plytron
Steel
Aluminium/
Titanium alloys
TEPEX
carbon/PA66
APC-2/SUPreM
1/1
APC-2/SUPreM
UD