Lightweight High-Performance Polymer Composite for Automotive Applications

Investigation of mechanical behavior of glass fiber reinforced extruded polystyrene core material composites

Layered composites are composite materials created by combining different layers of materials. Each layer can possess unique properties, often tailored to meet specific application or design requirements. These composites have found applications in various sectors due to their features, which include lightness, excellent impact properties, and customization according to specific application areas. In this study, glass fiber reinforced polymer foam core layered composite materials were produced. EPS polymer foam was used as the core material. During production, polymer foams and fibers were bonded to the upper and lower sides of the foams using resin. Samples were produced with 4 and 6 layers on both sides, totaling 8 and 12 layers, respectively. The vacuum bagging method was employed in production, utilizing the manual laying technique. Upon completion of production, the materials were cut into sizes conforming to standards and converted into samples. Subsequently, three-point bending and low-speed impact tests were conducted on the produced samples. As a result of the impact tests, perforation occurred in the 8-layer samples of 200 g m-2 glass fiber composites, while rebound was observed in the 12-layer samples. Although more deformation occurred in the 8-layer glass fiber composites of 300 g m-2 than in the 12-layer samples, both sets of experiments resulted in rebound. Similar results to the impact tests were obtained in three-point bending tests, with higher strengths observed in the 12-layer samples compared to the 8-layer samples. Composite samples with fiber layers of 300 g m-2 exhibited better performance than samples with 200 g m-2 fibers.

Ultra-High-Temperature Ceramic-Doped Inorganic Polymers for Thermo-Structural Fiber-Reinforced Composites

New inorganic nanostructured matrices for fiber-reinforced composites with enhanced high-temperature stability were developed from alkali aluminosilicate polymers doped with different ultra-high-temperature ceramic (UHTC) particles. The alkali aluminosilicate matrices were synthesized at room temperature with a high SiO2:Al2O3 ratio and then further functionalized by doping with 4-5 wt % of micrometric SiC, ZrB2, ZrC, and HfC powders and finally thermally stabilized as glass-ceramics at 750 °C. The different UHTC-doped matrices were characterized according to their dimensional and microstructural changes after thermal cycling in air flux at 1000 °C. The first results showed that carbide-based UHTC powders improved the thermal stability of the matrices, preventing the excessive swelling of the material and the formation of detrimental voids that might result in the lack of adhesion with reinforcing fibers. Contrarily, the addition of ZrB2 resulted in an excessive matrix swelling at high temperature, thus proving no efficacy compared to the undoped matrix. Impregnation tests carried out on C-fiber fabrics showed good processability, adhesion to the fibers, and fracture pull-out, especially for carbide-based matrices.

The degradation during recycling of polyamide 6 produced by anionic ring-opening polymerization of ε-caprolactam

As the plastics industry continues to grow, the amount of plastic waste is also increasing. The European Union is controlling plastic waste through various regulations, focusing primarily on recyclability. A good alternative to traditional thermoset composites is thermoplastic polyamide 6 composites produced by Thermoplastic Resin Transfer Molding (T-RTM). Polyamide 6 has high strength and is produced by in-situ anionic ring-opening polymerization in T-RTM. Products made with this technology can replace traditional thermoset composites in many areas, which greatly increases recyclability. In this paper, the recyclability of the high molecular weight polyamide 6 matrix material of T-RTM composites is investigated. Products were mechanically recycled and then processed by injection molding. Thermal, mechanical and rheological properties of the samples were compared with the properties of the original product, as well as a general injection molding-grade PA6. Results show that the parts prepared with this innovative technology can be mechanically recycled and reprocessed by injection molding without a processing aid. After reprocessing, a significant reduction in properties is observed due to degradation, but the properties of the resulting product are in good agreement with those of a conventional commercially available injection molding grade PA6 material.

The Relationships between the Structure and Properties of PA56 and PA66 and Their Fibers

Bio-based polymers can reduce dependence on nonrenewable petrochemical resources and will be beneficial for future sustainable developments due to their low carbon footprint. In this work, the feasibility of bio-based polyamide 56 (PA56) substituting petroleum-based PA66 is systematically investigated. The crystallization, melting, and decomposition temperature of PA56 were all lower than that of PA66. PA56 formed a γ crystal type with larger grain size and took a longer amount of time to complete the crystallization process since its crystallization rate was lower than that of PA66. Compared with PA66, PA56 exhibited a higher tensile strength of 71.3 ± 1.9 MPa and specific strength of 64.8 ± 2.0 MPa but lower notched impact strength. More importantly, the limited oxygen index and vertical combustion measurement results indicated that the flame retardancy of PA56 was better than PA66, and the LOI values and the UL94 result of PA56 were 27.6% ± 0.9% and V-2. It is worth noting that the PA56 fiber had superior biodegradability compared to the PA66 fiber. PA56 showed significant biodegradation from the eighth week, whereas PA66 remained clean until the sixteenth week (without obvious biodegradation taking place). Eventually, PA56 did not show significant differences compared to PA66 in terms of thermal and mechanical properties. However, PA56 had great advantages in flame retardancy and biodegradability, indicating that the bio-based PA56 could potentially replace petroleum-based PA66 in many fields.

Automatic dispersion, defect, curing, and thermal characteristics determination of polymer composites using micro-scale infrared thermography and machine learning algorithm

Infrared thermography is a non-destructive technique that can be exploited in many fields including polymer composite investigation. Based on emissivity and thermal diffusivity variation; components, defects, and curing state of the composite can be identified. However, manual processing of thermal images that may contain significant artifacts, is prone to erroneous component and property determination. In this study, thermal images of different graphite/graphene-based polymer composites fabricated by hand, planetary, and batch mixing techniques were analyzed through an automatic machine learning model. Filler size, shape, and location can be identified in polymer composites and thus, the dispersion of different samples was quantified with a resolution of ~ 20 µm despite having artifacts in the thermal image. Thermal diffusivity comparison of three mixing techniques was performed for 40% graphite in the elastomer. Batch mixing demonstrated superior dispersion than planetary and hand mixing as the dispersion index (DI) for batch mixing was 0.07 while planetary and hand mixing showed 0.0865 and 0.163 respectively. Curing was investigated for a polymer with different fillers (PDMS took 500 s while PDMS-Graphene and PDMS Graphite Powder took 800 s to cure), and a thermal characteristic curve was generated to compare the composite quality. Therefore, the above-mentioned methods with machine learning algorithms can be a great tool to analyze composite both quantitatively and qualitatively.

Production and Application of Polymer Foams Employing Supercritical Carbon Dioxide

Polymeric foams have characteristics that make them attractive for different applications. However, some foaming methods rely on chemicals that are not environmentally friendly. One of the possibilities to tackle the environmental issue is to utilize supercritical carbon dioxide ScCO2 since it is a “green” solvent, thus facilitating a sustainable method of producing foams. ScCO2 is nontoxic, chemically inert, and soluble in molten plastic. It can act as a plasticizer, decreasing the viscosity of polymers according to temperature and pressure. Most foam processes can benefit from ScCO2 since the methods rely on nucleation, growth, and expansion mechanisms. Process considerations such as pretreatment, temperature, pressure, pressure drop, and diffusion time are relevant parameters for foaming. Other variables such as additives, fillers, and chain extenders also play a role in the foaming process. This review highlights the morphology, performance, and features of the foam produced with ScCO2, considering relevant aspects of replacing or introducing a novel foam. Recent findings related to foaming assisted by ScCO2 and how processing parameters influence the foam product are addressed. In addition, we discuss possible applications where foams have significant benefits. This review shows the recent progress and possibilities of ScCO2 in processing polymer foams.

The Injected Foaming Study of Polypropylene/Multiwall Carbon Nanotube Composite with In Situ Fibrillation Reinforcement

This paper explored the injection foaming process of in situ fibrillation reinforced polypropylene composites. Using polypropylene (PP) as the continuous phase, polytetrafluoroethylene (PTFE) as the dispersed phase, multi-wall carbon nanotubes (MWCNTs) as the conductive filler, and PP grafted with maleic anhydride (PP-g-MA) as the compatibilizer, a MWCNTs/PP-g-MA masterbatch was prepared by using a solution blending method. Then, a lightweight, conductive PP/PTFE/MWCNTs composite foam was prepared by means of extruder granulation and supercritical nitrogen (ScN₂) injection foaming. The composite foams were studied in terms of rheology, morphological, foaming behavior and mechanical properties. The results proved that the in situ fibrillation of PTFE can have a remarkable effect on melt strength and viscoelasticity, thus improving the foaming performance; we found that PP/3% PTFE showed excellent performance. Meanwhile, the addition of MWCNTs endows the material with conductive properties, and the conductivity reached was 2.73 × 10^-5 S/m with the addition of 0.2 wt% MWCNTs. This study's findings are expected to be applied in the lightweight, antistatic and high-performance automotive industry.

An Injecting Molding Method for Forming the HFRP/PA6 Composite Parts

Carbon/glass fiber-reinforced polymer hybrid composite (HFRP) has the advantages of a light weight and high strength. For the lightweight design of automobile parts, composite parts made of HFRP and polymer materials are increasingly in demand. The method of the injection molding is usually adopted to fabricate composite part with HFRP and polymer materials. The connecting strength between the two materials has an important influence on the service life of the composite part. In this paper, HFRP and polyamide-6 (PA6) were used to fabricate a composite part by the injection molding method. In order to improve the connecting strength between HFRP and PA6, a kind of micro-grooves was fabricated on the HFRP surface. The micro-grooves on the surface of the HFRP provided sufficient adhesion and infiltrating space of molten PA6 material into the mold. In addition, the glass fiber in HFRP can also be used as nucleating agent to facilitate the rapid crystallization of PA6. The micro-grooves on the surface of HFRP were embedded into PA6 like nails, which could improve the connecting strength at the interface effectively. The paper investigated the effects of mold temperature, injection pressure, holding pressure and holding time on the injection quality and connecting strength of composite parts in detail. With a mold temperature of 240 °C, an injection pressure of 8 MPa, a holding pressure of 8 MPa and a holding time of 3 s, the maximum tensile strength of 10.68 MPa was obtained for the composite part. At the effect of micro-grooves, the tensile strength of the composite part could be increased by 126.27%.

Modelling and Simulation of MuCell®: The Effect of Key Processing Parameters on Cell Size and Weight Reduction

Microcellular injection moulding is an important injection moulding technique to create foaming plastic parts. However, there are no consistent conclusions on the impact of processing parameters on the cell morphology of microcellular injection moulded parts. This paper investigates the influence of the main processing parameters, such as melt temperature, mould temperature, injection pressure, flow rate, shot volume and gas dosage amount, on the average cell size and weight reduction of a talc-reinforced polypropylene square part (165 mm × 165 mm × 3.2 mm), using the commercial software Moldex 3D. The effect of each parameter is investigated considering a range of values and the simulation results were compared with published experimental results. The differences between numerical and experimental trends are discussed.

Multi-Response Optimisation of Automotive Door Using Grey Relational Analysis with Entropy Weights

Tail-welded blanks (TWBs) are widely used in automotive bodies to improve the structural performance and reduce weight. The stiffness and modal lightweight design optimisation of TWBs for automotive doors was performed in this study. The finite element model was validated through physical experiments. An L27 (3¹²) Taguchi orthogonal array was used to collect the sample points. The multi-objective optimisation problem was transformed into a single-objective optimisation problem based on the grey relational degree. The optimal combination of structural design parameters was obtained for a tail-welded door using the proposed method, and the weight of the door structure was reduced by 2.83 kg. The proposed optimisation method has fewer iterations and a lower computational cost, enabling the design of lightweight TWBs.

Welding and Riveting Hybrid Bonding of 6061 Al and Carbon Fiber Reinforced Composites

Welding and riveting hybrid bonding technology was applied to join 6061 aluminum alloy and carbon fiber reinforced plastics (CFRP). The laser-arc hybrid welding process and stepped rivets were used in the experiments to reduce the impact of the poor heat resistance of composites. The effect of hybrid welding arc current on the formation and mechanical properties of 6061 Al/CFRP joints was studied. Tensile shear load up to 4.65 kN was achieved by adjusting process parameters. The welding process and mode of the fracture were analyzed. The hybrid bonded joint obtained consisted of two parts: a welded joint of Al plate and Al rivet, and a bonded interface between Al plate and CFRP plate. The mechanical properties of the hybrid joint were mainly determined by the Al plate/Al rivet welded joint. The results of the study show that there are three interfacial bonding mechanisms between aluminum and CFRP. In addition to mechanical bonding between the Al plate and CFRP plate, there were also metallurgical bonding of Al-Mg intermetallic compounds with resin matrix and chemical reactions of aluminum with resin and carbon fibers at the interface, which could improve the mechanical properties of the joints.

Processing and Testing of Reinforced PA66 Based Composites

The new requirements in different sectors, such as aerospace, automotive and construction, for lightweight materials have led to an increase in demand for composite materials suitable for use in high rate production processes, such as plastic injection. This makes it necessary to look for matrices and reinforcements that, in addition to being compatible with each other, are also compatible with the injection process. It is in this area of research where the work presented here arises. To meet the two requirements mentioned above, this study contemplates a battery of composite materials obtained by combining PA66 and fiberglass, in different proportions and configuration, both for the preparation of the matrix and for reinforcement. For the elaboration of the matrix, two options have been evaluated, PA66 and PA66 reinforced at 35% with short glass fibre. To obtain reinforcement, six different options have been evaluated; two conventional fiberglass fabrics (each with different density) and four hybrid fabrics obtained from the previous ones by adding PA66 in different configurations (two over-stitched fabrics and two other fabrics). The different composite materials obtained were validated by means of the corresponding adhesion, peeling and resistance tests.

Basalt/Glass Fiber Polypropylene Hybrid Composites: Mechanical Properties at Different Temperatures and under Cyclic Loading and Micromechanical Modelling

Basalt/glass fiber polypropylene hybrid composites were developed as subjects of investigation, with the aim to characterize their properties. An injection molding machine was used to produce the test samples. The following three different tests, at various specimen temperatures, were conducted: tensile test, three-point flexural test, and Charpy impact test. To determine fatigue behavior, the samples were uniaxially loaded and unloaded. Mechanical hysteresis loops were recorded and the dissipation energy of each loop was calculated. To determine the adhesion and dispersion between the fibers and the matrix, the fractured surfaces of the various specimens, after the tensile test, were investigated using a scanning electron microscope. The results show that the production of a composite with both basalt and glass fibers, in a polypropylene matrix with maleic anhydride-grafted polypropylene, can be successfully achieved. The addition of the two types of fibers increased the tensile strength by 306% and the tensile modulus by 333% for a composition, with 20% by weight, of fibers. The material properties were estimated with the help of a simulation software, and validated with a FEA. A satisfactory correlation between the simulation and measurement data was achieved. The error lays in a range of 2% between the maximum stress values. At a lower strain (up to 0.02), the stress values are very well matched.

A Review on Microcellular Injection Moulding

Microcellular injection moulding (MuCell^®) is a polymer processing technology that uses a supercritical fluid inert gas, CO₂ or N₂, to produce light-weight products. Due to environmental pressures and the requirement of light-weight parts with good mechanical properties, this technology recently gained significant attention. However, poor surface appearance and limited mechanical properties still prevent the wide applications of this technique. This paper reviews the microcellular injection moulding process, main characteristics of the process, bubble nucleation and growth, and major recent developments in the field. Strategies to improve both the surface quality and mechanical properties are discussed in detail as well as the relationships between processing parameters, morphology, and surface and mechanical properties. Modelling approaches to simulate microcellular injection moulding and the mathematical models behind Moldex 3D and Moldflow, the two most commonly used software tools by industry and academia, are reviewed, and the main limitations are highlighted. Finally, future research perspectives to further develop this technology are also discussed.

High-Performance of a Thick-Walled Polyamide Composite Produced by Microcellular Injection Molding

Lightweight moldings obtained by microcellular injection molding (MIM) are of great significance for saving materials and reducing energy consumption. For thick-walled parts, the standard injection molding process brings some defects, including a sink mark, warpage, and high shrinkage. Polyamide 66 (PA66)/glass fiber (GF) thick-walled moldings were prepared by MuCell^® technology. The influences of moldings thickness (6 and 8.4 mm) and applied nitrogen pressure (16 and 20 MPa) on the morphology and mechanical properties were studied. Finally, the microcellular structure with a small cell diameter of about 30 μm was confirmed. Despite a significant time reduction of the holding phase (to 0.3 s), high-performance PA66 GF30 foamed moldings without sink marks and warpage were obtained. The excellent strength properties and favorable impact resistance while reducing the weight of thick-walled moldings were achieved. The main reason for the good results of polyamide composite was the orientation of the fibers in the flow direction and the large number of small nitrogen cells in the core and transition zone. The structure gradient was analysed and confirmed with scanning electron microscopy (SEM) images, X-ray micro computed tomography (micro CT) and finite element method (FEM) simulation.

Hybrid Polymer Composites Used in the Arms Industry: A Review

Polymer fiber composites are increasingly being used in many industries, including the defense industry. However, for protective applications, in addition to high specific strength and stiffness, polymer composites are also required to have a high energy absorption capacity. To improve the performance of fiber-reinforced composites, many researchers have modified them using multiple methods, such as the introduction of nanofillers into the polymer matrix, the modification of fibers with nanofillers, the impregnation of fabrics using a shear thickening fluid (STF) or a shear thickening gel (STG), or a combination of these techniques. In addition, the physical structures of composites have been modified through reinforcement hybridization; the appropriate design of roving, weave, and cross-orientation of fabric layers; and the development of 3D structures. This review focuses on the effects of modifying composites on their impact energy absorption capacity and other mechanical properties. It highlights the technologies used and their effectiveness for the three main fiber types: glass, carbon, and aramid. In addition, basic design considerations related to fabric selection and orientation are indicated. Evaluation of the literature data showed that the highest energy absorption capacities are obtained by using an STF or STG and an appropriate fiber reinforcement structure, while modifications using nanomaterials allow other strength parameters to be improved, such as flexural strength, tensile strength, or shear strength.

The Microcellular Structure of Injection Molded Thick-Walled Parts as Observed by In-Line Monitoring

The aim of the study was to detect the influence of nitrogen pressure on the rheological properties and structure of PA66 GF30 thick-walled parts, produced by means of microcellular injection molding (MIM), using the MuCell^® technology. The process was monitored in-line with pressure and temperature sensors assembled in the original injection mold. The measured data was subsequently used to evaluate rheological properties inside an 8.4 mm depth mold cavity. The analysis of the microcellular structure was related to the monitored in-line pressure and temperature changes during the injection process cycle. A four-times reduction of the maximum filling pressure in the mold cavity for MIM was found. At the same time, the holding pressure was taken over by expanding cells. The gradient effect of the cells distribution and the fiber arrangement in the flow direction were observed. A slight influence of nitrogen pressure on the cells size was found. Cells with a diameter lower than 20 µm dominate in the analyzed cases. An effect of reduction of the average cells size in the function of distance to the gate was observed. The creation of structure gradient and changes of cells dimensions were evaluated by SEM images and confirmed with the micro CT analysis.

Microstructure and Properties of Glass Fiber-Reinforced Polyamide/Nylon Microcellular Foamed Composites

The automobile and aerospace industries require lightweight and high-strength structural parts. Nylon-based microcellular foamed composites have the characteristics of high strength and the advantages of being lightweight as well as having a low production cost and high product dimensional accuracy. In this work, the glass fiber-reinforced nylon foams were prepared through microcellular injection molding with supercritical fluid as the blowing agent. The tensile strength and weight loss ratio of microcellular foaming composites with various injection rates, temperatures, and volumes were investigated through orthogonal experiments. Moreover, the correlations between dielectric constant and injection volume were also studied. The results showed that the "slow-fast" injection rate, increased temperature, and injection volume were beneficial to improving the tensile strength and strength/weight ratios. Meanwhile, the dielectric constant can be decreased by building the microcellular structure in nylon, which is associated with the weight loss ratio extent closely.

Effect of Exposure Temperature on the Crashworthiness of Carbon/Epoxy Composite Rectangular Tubes Under Quasi-Static Compression

The exposure of polymeric composites to thermal loading is a ubiquitous problem that leads to the degradation of mechanical properties, reducing the service life of an engineered structure, and potentially premature, catastrophic modes of failure. In the current paper, an experimental study is presented in order to investigate the effect of thermal exposure on the crushing performance of carbon fiber-reinforced plastic (CFRP) composite tubes. Specimens of rectangular tubes are subjected to thermal exposure at 90, 120, 150 and 180 °C before being crushed under quasi-static loading. The results showed a reduction in the peak load by increasing the aging temperature up to °C, which is followed by an increase in the peak load at 150 °C, due to post-curing. For the energy absorbed and the specific energy, a sharp reduction is recorded (up to 70% reduction) due to thermal aging. These results showed that the effect of thermal exposure on crashworthiness needs more attention during composites’ design, especially for transportation applications.

Shrinkage and Warpage Minimization of Glass-Fiber-Reinforced Polyamide 6 Parts by Microcellular Foam Injection Molding

Shrinkage and warpage of injection-molded parts can be minimized by applying microcellular foaming technology to the injection molding process. However, unlike the conventional injection molding process, the optimal conditions of the microcellular foam injection molding process are elusive because of core differences such as gas injection. Therefore, this study aims to derive process conditions to minimize the shrinkage and warpage of microcellular foam injection-molded parts made of glass fiber reinforced polyamide 6 (PA6/GF). Process factors and levels were first determined, with experiments planned accordingly. We simulated designed experiments using injection molding analysis software, and the results were analyzed using the Taguchi method, analysis of variance (ANOVA), and response surface methodology (RSM), with the ANOVA analysis being ultimately demonstrating the influence of the factors. We derived and verified the optimal combination of process factors and levels for minimizing both shrinkage and warpage using the Taguchi method and RSM. In addition, the mechanical properties and cell morphology of PA6/GF, which change with microcellular foam injection molding, were confirmed.

Correlation Between the Structure and Compressive Property of PMMA Microcellular Foams Fabricated by Supercritical CO2 Foaming Method

In this study, we fabricated poly (methyl methacrylate) (PMMA) microcellular foams featuring tunable cellular structures and porosity, through adjusting the supercritical CO₂ foaming conditions. Experimental testing and finite element model (FEM) simulations were conducted to systematically elucidate the influence of the foaming parameters and structure on compressive properties of the foam. The correlation between the cellular structure and mechanical properties was acquired by separating the effects of the cell size and foam porosity. It was found that cell size reduction contributes to improved mechanical properties, which can be attributed to the dispersion of stress and decreasing stress concentration.

A Novel Hybrid Foaming Method for Low-Pressure Microcellular Foam Production of Unfilled and Talc-Filled Copolymer Polypropylenes

Unfilled and talc-filled Copolymer Polypropylene (PP) samples were produced through low-pressure foam-injection molding (FIM). The foaming stage of the process has been facilitated through a chemical blowing agent (C₆H₇NaO₇ and CaCO₃ mixture), a physical blowing agent (supercritical N₂) and a novel hybrid foaming (combination of said chemical and physical foaming agents). Three weight-saving levels were produced with the varying foaming methods and compared to conventional injection molding. The unfilled PP foams produced through chemical blowing agent exhibited the strongest mechanical characteristics due to larger skin wall thicknesses, while the weakest were that of the talc-filled PP through the hybrid foaming technique. However, the hybrid foaming produced superior microcellular foams for both PPs due to calcium carbonate (CaCO₃) enhancing the nucleation phase.

Investigation of the Constitutive Model of W/PMMA Composite Microcellular Foams

Investigating the constitutive relationship of a material can provide better understanding of the mechanical properties of a material and has an irreplaceable effect on optimizing the performance of a material. This paper investigated a constitutive model for tungsten/polymethyl-methacrylate (W/PMMA) composite microcellular foams prepared by using melt mixing and supercritical carbon dioxide foaming. The stress-strain relationships of these foams with different W contents were measured under static compression. The elastic modulus and compressive strength values of the foams were remarkably greater than those of the pure PMMA foams: at a W content of 20 wt %, these values were increased by 269.1% and 123.9%, respectively. Based on the Maxwell constitutive model, the relevant coefficients were fitted according to the experimental data of different relative densities and W contents in quasi-static compression. According to the numerical relationships between the relevant coefficients and the relative densities and W contents, the quasi-static mechanical constitutive model of W/PMMA composite microcellular foams with W contents of 0~60 wt % and relative densities of 0.15~0.55 were predicted. This study provided basic data for the optimal design of the W/PMMA composite microcellular foams and proposed a method for investigating the mechanical properties of composite microcellular foam materials.