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School of Tech. and Management, Polytechnic Institute of Leiria, 2411-901 Leiria, Portugal
Institute of Polymers and Composites/I3N, Minho University, 4800-058 Guimaraes, Portugal
c
Dep. of Mechanical Engineering ISEP, 4200-072 Porto, Portugal
d
Department of Polymer Engineering, Minho University, 4800-058 Guimaraes, Portugal
e
DEMEGI / FEUP, 4200-465 Porto, Portugal
Abstract
The aim of this work is to optimize the production of new continuous carbon fibers reinforced polypropylene matrix
pre-impregnated materials (towpregs) continuously processed by dry deposition of polypropylene (PP) powder by our own
developed dry coating line. The processing of the produced towpregs by pultrusion, using a prototype equipment, was also
optimized. The optimization of both processes was made by studying the influence of the most relevant processing parameters in
the final properties of the produced towpregs and composites. The method of Taguchi/DOE (Design of Experiments) was used to
allow the determination of the optimal processing windows. The possibility of using maleic anhydride as compatibilizer for
polypropylene reinforced carbon fiber composites (CF/PP) was also analyzed. A pre-consolidate tape was produced by the melting
cross-head extrusion process and its proprieties compared with those of towpregs. Finally, towpregs were characterized by
scanning electron microscopy (SEM) and visual analysis. Their polymer mass contents were determined and the final pultruded
composite profiles were also submitted to tensile, interlaminar, flexural, calcination and optical microscopy tests.
2013 Sociedade Portuguesa de Materiais (SPM). Published by Elsevier Espaa, S.L. All rights reserved.
Keywords: towpreg; composite materials; thermoplastic; pultrusion; polypropylene; Taguchi/DOE.
This paper was presented at MATERIAIS 2013, Coimbra, Portugal, March 25-27, 2013
1. Introduction*
During the last decades, composites have successfully
replaced traditional materials in many engineering
applications due to its excellent properties, mainly
their excellent mechanical properties combined with
low density [1,2].
Although only recently thermoplastic matrices have
been used in long and continuous fiber reinforced
*
Corresponding author.
E-mail address: paulo.novo@ipleiria.pt (P.J. Novo)
2013 Sociedade Portuguesa de Materiais (SPM). Publicado por Elsevier Espaa, S.L. Todos os direitos reservados
http://dx.doi.org/10.1016/j.ctmat.2014.03.004
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P.J. Novo et al. / Cincia & Tecnologia dos Materiais 25 (2013) 8591
Property
PP granules
760
900
1.73
30
5490
1.1
294
Linear density
(Tex)
Specific gravity
(Mg/m3)
Tensile strength
(MPa)
Young Modulus
(GPa)
a
Yield Strength
2. Experimental
a) towpregs
Property
Linear density
(Tex)
Specific gravity
(Mg/m3)
Tensile strength
(MPa)
Young Modulus
(GPa)
Poissons ratio
Average powder
particle size
(m)
1
Yield Strength
PP powder
(ICORENE 9184B P)
Manufacturer
Experimental
datasheet
-
Carbon fiber
(TORAY M30 SC)
Manufacturer Typical
datasheet
values
760
1.73
1.75
19
5490
2600
1.3
0.98
294
170
0.21
440
163
0.91
30
0.91
1
2.2. Production
of
Thermoplastic
Pre-Impregnated Products
Matrix
P.J. Novo et al. / Cincia & Tecnologia dos Materiais 25 (2013) 8591
Z
87
(1)
1
2
3
4
5
6
7
8
9
600
600
600
650
650
650
700
700
700
350
400
420
350
400
420
350
400
420
4
6
8
8
4
6
6
8
4
Average
32.2
31.4
20.6
27.9
39.9
40.7
35.6
40.6
40.4
34.5
CROSS-HEAD
DIE
EXTRUDER SCREW
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P.J. Novo et al. / Cincia & Tecnologia dos Materiais 25 (2013) 8591
Description
Fiber type
Filament diameter
Fiber content
Matrix type
Tape width
Tape linear density
25 mm
14000 Tex
1
2
3
4
5
6
7
8
Furnace
Heating die
Linear
temperature temperature pulling speed
(C)
(C)
(m/min)
160
240
0.2
180
240
0.2
160
260
0.2
180
260
0.2
160
240
0.3
180
240
0.3
160
260
0.3
180
260
0.3
Flexural properties
Flexural
modulus
(GPa)
86.7 1.3
79.5 2.0
91.0 0.4
85.1 1.7
82.1 2.8
87.5 1.9
85.0 4.4
83.7 2.8
Flexural
strength
(MPa)
229.0 7.3
212.4 12.6
241.2 1.6
218.2 9.1
241.7 13.1
239.6 13.3
234.5 11.5
221.3 7.1
P.J. Novo et al. / Cincia & Tecnologia dos Materiais 25 (2013) 8591
89
Flexural properties
Flexural
Flexural
modulus
strength
(GPa)
(GPa)
229.0 7.3 87.6 1,3
191.7 7.8 70.4 2.8
237.4 11.8 80.5 2.6
Processing
parameters
Flexural modulus
(GPa)
Flexural strenght
(GPa)
With
additive
Without
additive
With
additive
Furnace
temperature (C) 160
Heating die
260 90.1 0.4 87.6 1.3
temperature (C)
Linear pulling
0,2
speed (m/min)
241.2 1.6
229.0 7.3
Without
additive
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P.J. Novo et al. / Cincia & Tecnologia dos Materiais 25 (2013) 8591
Property
Flexure
Modulus
(GPa)
Flexural
Towpreg
Towpreg with
addtive
PCT
Experimental
90.10.4
87.61.3
37.72.2
Theoretical
85.7
85.5
54.0
178.10.8
173.52.6
118.26.9
Experimental
241.21.6
229.07.3
158.74.2
Theoretical
1311.0
1308.4
825.8
476.73.2
453.514.5
497.513.2
110.65.9
106.16.3
63.54.3
Interlaminar
Shear
Tensile
Modulus
(GPa)
Experimental
85.7
85.5
54.0
Theoretical
218.611.7
210.112.5
199.113.5
12.30.3
13.00.4
14.00.2
50.6
50.5
31.9
3. Conclusions
PCT
P.J. Novo et al. / Cincia & Tecnologia dos Materiais 25 (2013) 8591
References
[1] S. Mazumdar, High Performance Composites, (May
2012).
[2] G. Bechtold, S. Wiedmer, K. Friedrich, J. Thermoplast.
Compos. Mater. 15, 443 (2002).
[3] J.F. Silva, J.P. Nunes, F.W. Van-Hattum, C.A. Bernardo
and A.T. Marques, Improving Low-Cost Continuous Fibre
91