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Matta A, Yadavalli VR, Manas L, Kadleckova M, Pavlinek V, Sedlacek T. Surface Treatments' Influence on the Interfacial Bonding between Glass Fibre Reinforced Elium ® Composite and Polybutylene Terephthalate. MATERIALS (BASEL, SWITZERLAND) 2024; 17:3276. [PMID: 38998358 PMCID: PMC11243668 DOI: 10.3390/ma17133276] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 05/21/2024] [Revised: 06/28/2024] [Accepted: 07/01/2024] [Indexed: 07/14/2024]
Abstract
This study examines the process of using injection moulding to join two different materials to manufacture bi-component moulded products with improved performance characteristics. The two-component process, which combines the advantages of two different technologies-the high efficiency of the injection moulding process and the excellent mechanical properties of long glass fibre composites produced by resin transfer moulding (RTM) technology-offers a particular advantage and improved applicability of the prepared lightweight products in both the automotive and aerospace sectors. The composite studied here consists of Elium® thermoplastic resin (30%) reinforced with unwoven glass fibre fabric (70%) using the RTM process. The Elium® composite sample is consequently used as an insert overmoulded with polybutylene terephthalate (PBT) homopolymer reinforced with 20% w/w of short glass fibre through injection moulding. The influence of different mould temperatures and surface treatments on the adhesion between the materials used is investigated by evaluating the mechanical performance using tensile shear strength tests. It was found that while an increase in mould temperature from 40 °C to 120 °C resulted in a doubling of the initial average bond strength between untreated Elium® RTM inserts and overmoulded PBT parts (0.9 MPa), sandblasting the inserts ensured a further tripling of the bond strength of the composites to a value of 5.4 MPa.
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Affiliation(s)
- Ashish Matta
- Department of Polymer Engineering, Faculty of Technology, Tomas Bata University in Zlin, Vavreckova 5669, 760 01 Zlin, Czech Republic;
| | - Venkat Reddy Yadavalli
- Department of Applied Logistics and Polymer Sciences, Hochschule Kaiserslautern, University of Applied Sciences, 67659 Pirmasens, Germany;
| | - Lukas Manas
- Centre of Polymer Systems, Tomas Bata University in Zlin, Trida Tomase Bati 5678, 760 01 Zlin, Czech Republic; (M.K.); (T.S.)
- Department of Production Engineering, Faculty of Technology, Tomas Bata University in Zlin, Vavreckova 5669, 760 01 Zlin, Czech Republic
| | - Marketa Kadleckova
- Centre of Polymer Systems, Tomas Bata University in Zlin, Trida Tomase Bati 5678, 760 01 Zlin, Czech Republic; (M.K.); (T.S.)
- Department of Physics and Materials Engineering, Faculty of Technology, Tomas Bata University in Zlin, Vavreckova 5669, 760 01 Zlin, Czech Republic
| | | | - Tomas Sedlacek
- Centre of Polymer Systems, Tomas Bata University in Zlin, Trida Tomase Bati 5678, 760 01 Zlin, Czech Republic; (M.K.); (T.S.)
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Birtha J, Marschik C, Kobler E, Straka K, Steinbichler G, Schlecht S, Zwicklhuber P. Optimizing the Process of Spot Welding of Polycarbonate-Matrix-Based Unidirectional (UD) Thermoplastic Composite Tapes. Polymers (Basel) 2023; 15:polym15092182. [PMID: 37177329 PMCID: PMC10181166 DOI: 10.3390/polym15092182] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/04/2023] [Revised: 04/26/2023] [Accepted: 04/28/2023] [Indexed: 05/15/2023] Open
Abstract
The aim of this work was to optimize spot welding of unidirectional tapes made of polycarbonate and carbon fibers. Three studies were performed to investigate the influences of various welding conditions on the quality of the welded spot. First, we used a full factorial experimental design to analyze the influence of temperature and time on the welds' tensile stress at break. Second, we repeated the experiment with optimized settings and conditions. Finally, we adopted a central composite design (CCD) to investigate the stability of the process. Our results show that temperature had the greatest influence on weld quality. The maximum tensile stress achieved was 23 MPa. Using a relatively high temperature for a short welding time resulted in self-cleaning of the welding head and in a faster and more stable process, and gel permeation chromatography (GPC) confirmed that these conditions caused no additional degradation.
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Affiliation(s)
- Janos Birtha
- Institute of Polymer Injection Moulding and Process Automation, Johannes Kepler University Linz, Altenbergerstraße 69, 4040 Linz, Austria
- Competence Center CHASE GmbH, Altenbergerstraße 69, 4040 Linz, Austria
| | | | - Eva Kobler
- Competence Center CHASE GmbH, Altenbergerstraße 69, 4040 Linz, Austria
| | - Klaus Straka
- Institute of Polymer Injection Moulding and Process Automation, Johannes Kepler University Linz, Altenbergerstraße 69, 4040 Linz, Austria
| | - Georg Steinbichler
- Institute of Polymer Injection Moulding and Process Automation, Johannes Kepler University Linz, Altenbergerstraße 69, 4040 Linz, Austria
| | - Sven Schlecht
- Covestro Deutschland AG, Kaiser-Wilhelm-Allee 60, 51373 Leverkusen, Germany
| | - Paul Zwicklhuber
- ENGEL AUSTRIA GmbH, Ludwig-Engel-Straße 1, 4311 Schwertberg, Austria
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Alexenko VO, Panin SV, Stepanov DY, Byakov AV, Bogdanov AA, Buslovich DG, Panin KS, Tian D. Ultrasonic Welding of PEEK Plates with CF Fabric Reinforcement-The Optimization of the Process by Neural Network Simulation. MATERIALS (BASEL, SWITZERLAND) 2023; 16:2115. [PMID: 36903230 PMCID: PMC10004364 DOI: 10.3390/ma16052115] [Citation(s) in RCA: 4] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 02/04/2023] [Revised: 02/25/2023] [Accepted: 03/02/2023] [Indexed: 06/18/2023]
Abstract
The optimal mode for ultrasonic welding (USW) of the "PEEK-ED (PEEK)-prepreg (PEI impregnated CF fabric)-ED (PEEK)-PEEK" lap joint was determined by artificial neural network (ANN) simulation, based on the sample of the experimental data expanded with the expert data set. The experimental verification of the simulation results showed that mode 10 (t = 900 ms, P = 1.7 atm, τ = 2000 ms) ensured the high strength properties and preservation of the structural integrity of the carbon fiber fabric (CFF). Additionally, it showed that the "PEEK-CFF prepreg-PEEK" USW lap joint could be fabricated by the "multi-spot" USW method with the optimal mode 10, which can resist the load per cycle of 50 MPa (the bottom HCF level). The USW mode, determined by ANN simulation for the neat PEEK adherends, did not provide joining both particulate and laminated composite adherends with the CFF prepreg reinforcement. The USW lap joints could be formed when the USW durations (t) were significantly increased up to 1200 and 1600 ms, respectively. In this case, the elastic energy is transferred more efficiently to the welding zone through the upper adherend.
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Affiliation(s)
- Vladislav O. Alexenko
- Laboratory of Mechanics of Polymer Composite Materials, Institute of Strength Physics and Materials Science of Siberian Branch of Russian Academy of Sciences, 634055 Tomsk, Russia
| | - Sergey V. Panin
- Laboratory of Mechanics of Polymer Composite Materials, Institute of Strength Physics and Materials Science of Siberian Branch of Russian Academy of Sciences, 634055 Tomsk, Russia
- Department of Materials Science, Engineering School of Advanced Manufacturing Technologies, National Research Tomsk Polytechnic University, 634050 Tomsk, Russia
| | - Dmitry Yu. Stepanov
- Laboratory of Mechanics of Polymer Composite Materials, Institute of Strength Physics and Materials Science of Siberian Branch of Russian Academy of Sciences, 634055 Tomsk, Russia
| | - Anton V. Byakov
- Laboratory of Mechanics of Polymer Composite Materials, Institute of Strength Physics and Materials Science of Siberian Branch of Russian Academy of Sciences, 634055 Tomsk, Russia
| | - Alexey A. Bogdanov
- Laboratory of Mechanics of Polymer Composite Materials, Institute of Strength Physics and Materials Science of Siberian Branch of Russian Academy of Sciences, 634055 Tomsk, Russia
- Department of Materials Science, Engineering School of Advanced Manufacturing Technologies, National Research Tomsk Polytechnic University, 634050 Tomsk, Russia
| | - Dmitry G. Buslovich
- Laboratory of Nanobioengineering, Institute of Strength Physics and Materials Science of Siberian Branch of Russian Academy of Sciences, 634055 Tomsk, Russia
| | - Konstantin S. Panin
- Department of Chemical Physics, Institute for Laser and Plasma Technologies, National Research Nuclear University MEPhI, 115409 Moscow, Russia
| | - Defang Tian
- Department of Materials Science, Engineering School of Advanced Manufacturing Technologies, National Research Tomsk Polytechnic University, 634050 Tomsk, Russia
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On the Addition of Multifunctional Methacrylate Monomers to an Acrylic-Based Infusible Resin for the Weldability of Acrylic-Based Glass Fibre Composites. Polymers (Basel) 2023; 15:polym15051250. [PMID: 36904491 PMCID: PMC10007228 DOI: 10.3390/polym15051250] [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: 01/27/2023] [Revised: 02/21/2023] [Accepted: 02/26/2023] [Indexed: 03/05/2023] Open
Abstract
The melt strength of Elium® acrylic resin is an important factor to ensure limited fluid flow during welding. To provide Elium® with a suitable melt strength via a slight crosslink, this study examines the effect of two dimethacrylates, namely butanediol-di-methacrylate (BDDMA) and tricyclo-decane-dimethanol-di-methacrylate (TCDDMDA), on the weldability of acrylic-based glass fibre composites. The resin system impregnating a five-layer woven glass preform is a mixture of Elium® acrylic resin, an initiator, and each of the multifunctional methacrylate monomers in the range of 0 to 2 parts per hundred resin (phr). Composite plates are manufactured by vacuum infusion (VI) at an ambient temperature and welded by using the infrared (IR) welding technique. The mechanical thermal analysis of the composites containing multifunctional methacrylate monomers higher than 0.25 phr shows a very little strain for the temperature range of 50 °C to 220 °C. The quantity of 0.25 phr of both of the multifunctional methacrylate monomers in the Elium® matrix improves the maximum bound shear strength of the weld by 50% compared to those compositions without the multifunctional methacrylate monomers.
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Gohel G, Soh CZ, Leong KF, Gerard P, Bhudolia SK. Effect of PMMA Coupling Layer in Enhancing the Ultrasonic Weld Strength of Novel Room Temperature Curable Acrylic Thermoplastic to Epoxy Based Composites. Polymers (Basel) 2022; 14:polym14091862. [PMID: 35567030 PMCID: PMC9105686 DOI: 10.3390/polym14091862] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/04/2022] [Revised: 04/28/2022] [Accepted: 04/28/2022] [Indexed: 02/04/2023] Open
Abstract
The joining of composites can be performed in an extremely short time with more energy-efficient ultrasonic welding techniques. The current research investigated the performance optimization of ultrasonic welding of carbon/Elium® composite to carbon/epoxy composite using a polymethyl methacrylate (PMMA) coupling interlayer. The weld strength was quantified by static lap shear strength (LSS) testing. A new methodology was used by creating a PMMA coupling layer on the epoxy composite adherend to achieve an improved interphase and thus enhance the weld properties. The LSS of Elium (EL)-Epoxy (EP) _0.25_0.25 was found to be 190% higher compared to that of EL-EP, confirming the effectiveness of the strategy used for creating an interlayer thermoplastic coupling layer. The time required for welding was optimized to be 2s as compared to 10 min required for adhesive bonding. Scanning electron microscopic images of epoxy and PMMA/Elium matrix interphase were observed to have a rough surface and remained largely unaffected by welding. There was an interphase change further away from the interphase to a rougher texture. There was little to no effect on the penultimate layer on the weld strength, as no interphase change could be observed after welding. Fractography investigation revealed shear cusps, matrix plastic deformation, fiber imprints, fiber pull-out, and good adhesion between matrix and fiber, features seen for configuration with maximum LSS. The current research findings present a way to join Elium® with epoxy composites that could be used in applications that require a selective strengthening, such as in sporting goods and consumer products. Furthermore, a detailed investigation is ongoing to use different filler particles and coupling layers to reach the maximum welding performance.
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Affiliation(s)
- Goram Gohel
- School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Avenue, Singapore 639798, Singapore; (C.Z.S.); (K.F.L.)
- Correspondence: (G.G.); (S.K.B.)
| | - Chun Zhi Soh
- School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Avenue, Singapore 639798, Singapore; (C.Z.S.); (K.F.L.)
| | - Kah Fai Leong
- School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Avenue, Singapore 639798, Singapore; (C.Z.S.); (K.F.L.)
| | - Pierre Gerard
- Groupement de Recherche de Lacq, Arkema, Route Départementale 817, BP 34, 64170 Lacq, France;
| | - Somen K. Bhudolia
- School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Avenue, Singapore 639798, Singapore; (C.Z.S.); (K.F.L.)
- Correspondence: (G.G.); (S.K.B.)
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Bhudolia SK, Gohel G, Vasudevan D, Leong KF, Gerard P. Behaviour of Rectangular Hollow Thin Ply Carbon Thermoset and Thermoplastic Composite Tubes Subjected to Bending. Polymers (Basel) 2022; 14:polym14071386. [PMID: 35406259 PMCID: PMC9003124 DOI: 10.3390/polym14071386] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/15/2022] [Revised: 03/24/2022] [Accepted: 03/26/2022] [Indexed: 11/30/2022] Open
Abstract
Tubular composites are widely used in many industrial applications, and there is need to use new material and reliable manufacturing processes to improve the performance and process aspects. The current research presents a detailed study to understand the flexure response of rectangular tubular composites based on thin ply carbon fibres and Elium® resin. Another aim was to understand the failure mechanisms of novel tubular thermoplastic composite systems and carry out a baseline comparison with Epoxy-based tubular systems. In the current research, a bladder-assisted resin transfer moulding process was used to manufacture hollow thermoplastic composite tubes, and the bending behaviour of thin ply carbon (TPC) composite parts with novel Elium® (EL) and Epoxy (EP) resin as the matrix material was studied using a detailed experimental study. A testing method with optimized support span and a saddle was used to carry out three-point bending tests on the tubular composite structures. The TPC/EL composite tubes have shown 10% higher bending strength, with a noticeable increase in deformation due the presence of extended plasticity attributes for acrylic Elium resin. Failure mechanisms studied with the detailed microscopic investigation have shown severe catastrophic failure for epoxy-based composite tubes; however, acrylic Elium®-based composite tubes have shown different damage modes such as fibre splitting, resin infragmentation, and fibre resin-interfacial cracking.
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Affiliation(s)
- Somen K. Bhudolia
- School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50, Nanyang Avenue, Singapore 639798, Singapore; (G.G.); (K.F.L.)
- Correspondence:
| | - Goram Gohel
- School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50, Nanyang Avenue, Singapore 639798, Singapore; (G.G.); (K.F.L.)
| | - Durga Vasudevan
- Technical University of Munich Asia, 25 International Business Park Rd, Singapore 609916, Singapore;
| | - Kah Fai Leong
- School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50, Nanyang Avenue, Singapore 639798, Singapore; (G.G.); (K.F.L.)
| | - Pierre Gerard
- Groupement de Recherche de Lacq, Arkema, Route Départementale 817, BP 34, 64170 Lacq, France;
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Frederick H, Li W, Palardy G. Disassembly Study of Ultrasonically Welded Thermoplastic Composite Joints via Resistance Heating. MATERIALS 2021; 14:ma14102521. [PMID: 34066277 PMCID: PMC8152058 DOI: 10.3390/ma14102521] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 04/19/2021] [Revised: 05/04/2021] [Accepted: 05/10/2021] [Indexed: 11/21/2022]
Abstract
This manuscript explores the disassembly potential of ultrasonically welded thermoplastic composite joints for reuse or recycling through resistance heating via a nanocomposite film located at the welded interface. Nanocomposite films containing multi-walled carbon nanotubes (MWCNTs) were characterized for thermo-electrical behavior to assess self-heating. It was generally observed that maximum temperature increased with MWCNT and film thickness. To demonstrate potential for disassembly, glass fiber/polypropylene adherends were welded with nanocomposite films. Shear stress during disassembly was measured for three initial adherend’s surface temperatures. It was found that the required tensile load decreased by over 90% at the highest temperatures, effectively demonstrating the potential for disassembly via electrically conductive films. Fracture surfaces suggested that disassembly was facilitated through a combination of nanocomposite and matrix melting and weakened fiber–matrix interface. Limitations, such as slow heating rates and the loss of contact at the interface, imply that the method could be more suited for recycling, instead of repair and reuse, as the heat-affected zone extended through the adherends’ thickness at the overlap during heating.
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Minchenkov K, Vedernikov A, Safonov A, Akhatov I. Thermoplastic Pultrusion: A Review. Polymers (Basel) 2021; 13:polym13020180. [PMID: 33419119 PMCID: PMC7825514 DOI: 10.3390/polym13020180] [Citation(s) in RCA: 22] [Impact Index Per Article: 7.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/12/2020] [Revised: 12/28/2020] [Accepted: 12/30/2020] [Indexed: 11/16/2022] Open
Abstract
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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