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Sidlipura S, Ayadi A, Lagardère Deléglise M. Assessing Intra-Bundle Impregnation in Partially Impregnated Glass Fiber-Reinforced Polypropylene Composites Using a 2D Extended-Field and Multimodal Imaging Approach. Polymers (Basel) 2024; 16:2171. [PMID: 39125198 PMCID: PMC11315057 DOI: 10.3390/polym16152171] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/25/2024] [Revised: 07/25/2024] [Accepted: 07/26/2024] [Indexed: 08/12/2024] Open
Abstract
This study evaluates multimodal imaging for characterizing microstructures in partially impregnated thermoplastic matrix composites made of woven glass fiber and polypropylene. The research quantifies the impregnation degree of fiber bundles within composite plates manufactured through a simplified compression resin transfer molding process. For comparison, a reference plate was produced using compression molding of film stacks. An original surface polishing procedure was introduced to minimize surface defects while polishing partially impregnated samples. Extended-field 2D imaging techniques, including polarized light, fluorescence, and scanning electron microscopies, were used to generate images of the same microstructure at fiber-scale resolutions throughout the plate. Post-processing workflows at the macro-scale involved stitching, rigid registration, and pixel classification of FM and SEM images. Meso-scale workflows focused on 0°-oriented fiber bundles extracted from extended-field images to conduct quantitative analyses of glass fiber and porosity area fractions. A one-way ANOVA analysis confirmed the reliability of the statistical data within the 95% confidence interval. Porosity quantification based on the conducted multimodal approach indicated the sensitivity of the impregnation degree according to the layer distance from the pool of melted polypropylene in the context of simplified-CRTM. The findings underscore the potential of multimodal imaging for quantitative analysis in composite material production.
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Affiliation(s)
| | - Abderrahmane Ayadi
- IMT Nord Europe, Institut Mines-Télécom, Univ. Lille, Centre for Materials and Processes, 59000 Lille, France
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Campos D, Maimí P, Martín A. Statistical Study of the Process Parameters for Achieving Continuous Consolidation of a Thermoplastic Composite. MATERIALS (BASEL, SWITZERLAND) 2023; 16:6723. [PMID: 37895705 PMCID: PMC10608415 DOI: 10.3390/ma16206723] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 09/03/2023] [Revised: 10/09/2023] [Accepted: 10/11/2023] [Indexed: 10/29/2023]
Abstract
Manufacturing components using thermoplastic composite materials necessitates a judicious balance among fabrication parameters, cost considerations and the ultimate quality of the elements produced. Continuous manufacturing technologies, exemplified by methods such as continuous compressing molding and glide forming, seek to revolutionize production through their continuous processing approach. This study aimed to investigate the effects different process parameters have on the final quality of the manufactured parts when a continuous manufacturing technology, such as glide forming, is applied to thermoplastic composite materials. An experimental rig was designed, and 19 samples were prepared using a unidirectional-carbon-fiber-reinforced LM-PAEK (low-melting polyaryletherketone) composite. The process parameters studied were temperature, pressure and forming speed. The quality of the final parts was evaluated based on their thickness and consolidation levels. The findings underscore the feasibility of leveraging continuous manufacturing technologies for producing components using thermoplastic composite materials, but the process parameters must be carefully controlled to ensure the quality of the final part. The models obtained could be used as a post-processing tool to predict thickness and consolidation levels when simulating the manufacture of a component on macroscale levels. Further research is needed to optimize the process parameters and study their effects on other thermoplastic composite materials.
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Affiliation(s)
- Daniel Campos
- AMADE-UdG Research Group, University of Girona, 17003 Girona, Spain;
- Applus+ Laboratories, 08193 Bellaterra, Spain;
| | - Pere Maimí
- AMADE-UdG Research Group, University of Girona, 17003 Girona, Spain;
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Dobránsky J, Gombár M, Stejskal T. The Influence of the Use of Technological Waste and the Simulation of Material Lifetime on the Unnotched Impact Strength of Two Different Polymer Composites. MATERIALS (BASEL, SWITZERLAND) 2022; 15:8516. [PMID: 36500011 PMCID: PMC9738518 DOI: 10.3390/ma15238516] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 11/16/2022] [Revised: 11/25/2022] [Accepted: 11/27/2022] [Indexed: 06/17/2023]
Abstract
The article deals with the assessment of the impact of technological polymer waste resulting from plastic injection technology and the subsequent simulation of the lifetime of polymer products on the impact strength of two different polymer composites. Two different types of polymer composites used to produce plastic parts in the automotive industry were chosen for the research. Based on the evaluation of the PBT composite before exposing the specimens to elevated temperature, it can be concluded that the concentration of the recycled material in the virgin material only affects the values of the unnotched impact strength of the PBT composite when the recycled material accounts for at least 50 wt.%. The results of the unnotched impact strength of the test specimens exposed at 150 °C/500 h make it evident that the addition of recycled material to the virgin material significantly reduces the components' service lives. The same trend could be observed with the second tested composite material, PPA.
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Affiliation(s)
- Jozef Dobránsky
- Faculty of Manufacturing Technologies with a Seat in Presov, Technical University of Kosice, Sturova 31, 080 01 Presov, Slovakia
| | - Miroslav Gombár
- Faculty of Management and Business, University of Presov, Namestie Legionarov 3, 080 01 Presov, Slovakia
| | - Tomáš Stejskal
- Faculty of Mechanical Engineering, Technical University of Kosice, Letna 9, 042 00 Kosice, Slovakia
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Huzaim NHM, Rahim SZA, Musa L, Abdellah AEH, Abdullah MMAB, Rennie A, Rahman R, Garus S, Błoch K, Sandu AV, Vizureanu P, Nabiałek M. Potential of Rapid Tooling in Rapid Heat Cycle Molding: A Review. MATERIALS 2022; 15:ma15103725. [PMID: 35629751 PMCID: PMC9144764 DOI: 10.3390/ma15103725] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 04/09/2022] [Revised: 05/01/2022] [Accepted: 05/12/2022] [Indexed: 02/01/2023]
Abstract
Rapid tooling (RT) and additive manufacturing (AM) are currently being used in several parts of industry, particularly in the development of new products. The demand for timely deliveries of low-cost products in a variety of geometrical patterns is continuing to increase year by year. Increased demand for low-cost materials and tooling, including RT, is driving the demand for plastic and rubber products, along with engineering and product manufacturers. The development of AM and RT technologies has led to significant improvements in the technologies, especially in testing performance for newly developed products prior to the fabrication of hard tooling and low-volume production. On the other hand, the rapid heating cycle molding (RHCM) injection method can be implemented to overcome product surface defects generated by conventional injection molding (CIM), since the surface gloss of the parts is significantly improved, and surface marks such as flow marks and weld marks are eliminated. The most important RHCM technique is rapid heating and cooling of the cavity surface, which somewhat improves part quality while also maximizing production efficiencies. RT is not just about making molds quickly; it also improves molding productivity. Therefore, as RT can also be used to produce products with low-volume production, there is a good potential to explore RHCM in RT. This paper reviews the implementation of RHCM in the molding industry, which has been well established and undergone improvement on the basis of different heating technologies. Lastly, this review also introduces future research opportunities regarding the potential of RT in the RHCM technique.
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Affiliation(s)
| | - Shayfull Zamree Abd Rahim
- Faculty of Mechanical Engineering and Technology, Universiti Malaysia Perlis, Arau 02600, Malaysia;
- Center of Excellence Geopolymer and Green Technology (CEGeoGTech), Universiti Malaysia Perlis, Kangar 01000, Malaysia; (L.M.); (M.M.A.B.A.); (R.R.)
- Correspondence: (S.Z.A.R.); (P.V.)
| | - Luqman Musa
- Center of Excellence Geopolymer and Green Technology (CEGeoGTech), Universiti Malaysia Perlis, Kangar 01000, Malaysia; (L.M.); (M.M.A.B.A.); (R.R.)
- Faculty of Chemical Engineering and Technology, Universiti Malaysia Perlis, Kangar 01000, Malaysia
| | - Abdellah El-hadj Abdellah
- Laboratory of Mechanics, Physics and Mathematical Modelling (LMP2M), University of Medea, Medea 26000, Algeria;
| | - Mohd Mustafa Al Bakri Abdullah
- Center of Excellence Geopolymer and Green Technology (CEGeoGTech), Universiti Malaysia Perlis, Kangar 01000, Malaysia; (L.M.); (M.M.A.B.A.); (R.R.)
- Faculty of Chemical Engineering and Technology, Universiti Malaysia Perlis, Kangar 01000, Malaysia
| | - Allan Rennie
- Lancaster Product Development Unit, Engineering Department, Lancaster University, Lancaster LA1 4YW, UK;
| | - Rozyanti Rahman
- Center of Excellence Geopolymer and Green Technology (CEGeoGTech), Universiti Malaysia Perlis, Kangar 01000, Malaysia; (L.M.); (M.M.A.B.A.); (R.R.)
- Faculty of Chemical Engineering and Technology, Universiti Malaysia Perlis, Kangar 01000, Malaysia
| | - Sebastian Garus
- Faculty of Mechanical Engineering and Computer Science, Częstochowa Univerity of Technology, 42-201 Częstochowa, Poland;
| | - Katarzyna Błoch
- Department of Physics, Częstochowa University of Technology, 42-201 Częstochowa, Poland; (K.B.); (M.N.)
| | - Andrei Victor Sandu
- Faculty of Materials Science and Engineering, Gheorghe Asachi Technical University of Iasi, 41 D. Mangeron Street, 700050 Iasi, Romania;
- Romanian Inventors Forum, Str. Sf. P. Movila 3, 700089 Iasi, Romania
| | - Petrica Vizureanu
- Faculty of Materials Science and Engineering, Gheorghe Asachi Technical University of Iasi, 41 D. Mangeron Street, 700050 Iasi, Romania;
- Technical Sciences Academy of Romania, Dacia Blvd 26, 030167 Bucharest, Romania
- Correspondence: (S.Z.A.R.); (P.V.)
| | - Marcin Nabiałek
- Department of Physics, Częstochowa University of Technology, 42-201 Częstochowa, Poland; (K.B.); (M.N.)
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Běhálek L, Dobránsky J, Pollák M, Borůvka M, Brdlík P. Application of Physical Methods for the Detection of a Thermally Degraded Recycled Material in Plastic Parts Made of Polypropylene Copolymer. MATERIALS 2021; 14:ma14030552. [PMID: 33498867 PMCID: PMC7865448 DOI: 10.3390/ma14030552] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 12/23/2020] [Revised: 01/18/2021] [Accepted: 01/20/2021] [Indexed: 11/26/2022]
Abstract
The paper deals with the possibility of applying physical methods to detect a thermally degraded recycled material in plastic parts made of polypropylene. Standard methods of evaluating the mechanical properties of the material under static tensile and bending stress, as well as under dynamic impact stress using the Charpy method, were used for the experimental measurements. The rheological properties of materials were monitored using a method involving measuring the melt flow index, while their thermal properties and oxidative stability were monitored using differential scanning calorimetry. Based on the methods used, it can be clearly stated that the most suitable technique for detecting thermally degraded recycled material in polypropylene is the method involving establishing the melt flow index. The bending test seems to be the most suitable method for detecting recycled material by measuring the material’s mechanical properties. Similarly to the melt volume flow rate (MVR) method, it was possible to unambiguously detect the presence of even a small amount of recycled material in the whole from measuring the material’s bending properties. It is clear from the results that in the short term, there may be no change in the useful properties of the parts, but in the long term the presence of degraded recycled material will have adverse consequences on their lifespan.
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Affiliation(s)
- Luboš Běhálek
- Faculty of Mechanical Engineering, Technical University of Liberec, Studentská 2, 461 17 Liberec, Czech Republic; (L.B.); (M.B.); (P.B.)
| | - Jozef Dobránsky
- Faculty of Manufacturing Technologies with a Seat in Presov, Technical University of Kosice, Bayerova 1, 080 01 Presov, Slovakia;
- Correspondence: ; Tel.: +421-55-602-6350
| | - Martin Pollák
- Faculty of Manufacturing Technologies with a Seat in Presov, Technical University of Kosice, Bayerova 1, 080 01 Presov, Slovakia;
| | - Martin Borůvka
- Faculty of Mechanical Engineering, Technical University of Liberec, Studentská 2, 461 17 Liberec, Czech Republic; (L.B.); (M.B.); (P.B.)
| | - Pavel Brdlík
- Faculty of Mechanical Engineering, Technical University of Liberec, Studentská 2, 461 17 Liberec, Czech Republic; (L.B.); (M.B.); (P.B.)
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