Decomposition Kinetics and Lifetime Estimation of Thermoplastic Composite Materials Reinforced with rCFRP

Because of the high demand for carbon fiber reinforced polymer (CFRP) materials across all industries, the reuse and/or recycling of these materials (rCFRP) is necessary in order to meet the principles of the circular economy, including recycling and reuse. The objective of this study is to estimate the lifespan of thermoplastic matrix composite materials reinforced with waste materials (CFRP), which undergo only a mechanical cutting process. This estimation is carried out through the thermal decomposition of polymers, including polymer matrix composite materials, which is a complex process due to the numerous reactions involved. Some authors calculate these kinetic parameters using thermogravimetric analysis (TGA) as it is a quick method, and it allows the identification of gases released during decomposition, provided that the equipment is prepared for it. This study includes a comparison between polyamides 11 and 12, as well as between polyamide composite materials with carbon fiber (CF) and polyamides reinforced with CF/epoxy composite material. The latter is treated with plasma to improve adhesion with polyamides. The behavior of weight as a function of temperature was studied at speeds of 3, 6, 10, 13, 17, and 20 °C/min, finding stability of the polyamides up to a temperature of 400 °C, which was consistent with the analysis by mass spectroscopy, where gas evolution is evident after 400 °C. The estimation of the lifespan was carried out using two different methods including the Toop equation and the free kinetics model (MFK). The energy of the decomposition process was determined using the MFK model, which establishes the energy as a function of the degree of conversion. It is estimated that at 5% decomposition, mechanical properties are lost.

Characterization of Polymeric Composites for Hydrogen Tank

Carbon neutrality has led to a surge in the popularity of hydrogen tanks in recent years. However, designing high-performance tanks necessitates the precise determination of input material properties. Unfortunately, conventional characterization methods often underestimate these material properties. To address this limitation, the current research introduces alternative designs of ring tensile specimens, which enable accurate and reliable characterization of filament-wound structures. The advantages and disadvantages of these alternative designs are thoroughly discussed, considering both numerical simulations and experimental investigations. Moreover, the proposed ring tensile methods are applied to characterize thermoplastic composites for hydrogen storage tanks. The results indicate that the mechanical strengths and stiffness of carbon fiber-reinforced thermoplastic Elium® 591 composites closely match those of epoxy-based composites. This newfound accuracy in measurement is expected to contribute significantly to the development of recyclable hydrogen tanks.

Enhancement of the Mechanical Performance of Glass-Fibre-Reinforced Composites through the Infusion Process of a Thermoplastic Recyclable Resin

Mechanical testing of glass-fibre-reinforced composite (GFRP) plates made of twill fabric and a thermoplastic recyclable infusion resin is presented. The considered thermoplastic resin, ELIUM®, is made of poly-methylmethacrylate and can be infused with properly tuned vacuum techniques, in the same manner as all liquid resin. Tensile, flexural, and drop-dart impact tests were carried out to assess the mechanical properties of the composites considering different fabrication conditions, such as the different degassing pressure before infusion and three different infusion vacuum pressures. The work reports a methodology to infuse ELIUM resin at a relatively high vacuum pressure of 0.8 bar. X-ray microtomography analysis showed that the produced laminates are free of defects, differently from what was reported in the literature, where void problems related to a vacuum infusion pressure higher than 0.3-0.5 bar were pointed out. Vacuum pressure values influence the mechanical characteristics of the laminate: when higher vacuum pressures are adopted, the mechanical properties of the GFRP laminates are enhanced and higher values of elastic modulus and strength are obtained. On the other hand, degassing the resin before infusion does not influence the mechanical properties of the laminates. A maximum bending and tensile strength of 420 and 305 MPa were reached by using the vacuum infusion of 0.8 bar with an elastic modulus of 18.5 and 20.6 GPa, respectively. The density of the produced laminates increases at higher vacuum infusion pressure up to a maximum value of 1.81 g/cm3 with the fibre volume fraction of each laminate.

Fabrication and Characterization of EVA Resins as Adhesives in Plywood

The practical problem of free formaldehyde pollution in the plywood industry is that polyethylene films have been shown to be able to replace some urea-formaldehyde resins for wood adhesives. To broaden the variety of thermoplastic plywood, reduce the hot-press temperature, and save energy consumption, an ethylene-vinyl acetate (EVA) film was selected as a wood adhesive to manufacture a novel wood-plastic composite plywood via hot-press and secondary press processes. The effects of the hot-press and secondary press processes at different levels on the physical-mechanical properties of EVA plywood (tensile shear strength, 24 h water absorption, and immersion peel performance) were evaluated. The results showed that the properties of the resulting plywood using the EVA film as an adhesive could meet the type III plywood standard. The optimum hot-press time was 1 min/mm, the hot-press temperature was 110-120 °C, the hot-press pressure was 1 MPa, the dosage film was 163 g/m², the secondary press time was 5 min, the secondary press pressure was 0.5 MPa, and the secondary press temperature was 25 °C. EVA plywood can be used in indoor environments.

Evaluation of dimensional stability, compressive resistance, and detail reproduction of thermoplastic resin (BDIMPRESS), elastomeric and composite bite registration material: An in vitro study

Aim

The fabrication of an accurate prosthesis depends mainly on precise recording of the maxillo-mandibular relationship of the patient and transferring it to the articulator. BDIMPRESS is a new thermoplastic material that has been proposed as a potential material to be used as an inter-occlusal registration, but there has been no literature evidence regarding its application as a bite registration. The main purpose of this study is to evaluate and compare the dimensional stability, detail reproduction, and compressive resistance of new interocclusal recording material with other two commonly used materials.

Settings and Design

In Vitro Comparative study.

Materials and Methods

The study was conducted according to ADA Specification standards of testing for dimensional stability, detail reproduction and compressive resistance. Specimens were prepared for three different materials (Thermoplastic resin, Polyvinyl siloxane, and Bis- acrylic) with 12 samples each.

Statistical Analysis Used

One way ANOVA was done for statistical analysis.

Results

Polyvinyl siloxane material was dimensionally stable (mean at 1 hr: 24.928 mm; 24 hrs: 24.919 mm & 48 hrs: 24.912 mm) followed by Bis- acrylic material (mean at 1 hr: 24.851 mm; 24 hrs: 24.825 mm & 48 hrs: 24.815 mm). On one way ANOVA, strong significance was observed between groups (P = 0.00). Thermoplastic resin showed higher amount of detail reproduction with 10 (out of 12 samples) samples showing satisfactory results. While bis- acrylic material showed the least compressive resistance (Strain %: 0.484%; Displacement- 0.0990mm). One-way ANOVA showed presence of significance between the groups (P = 0.024).

Conclusion

Polyvinyl siloxane showed superior dimensional stability, thermoplastic resin showed better detail reproduction and bis- acrylic showed high resistance to compression over other materials.

Evaluation of Microscopic Damage of PEEK Polymers under Cyclic Loadings Using Molecular Dynamics Simulations

Full-atomic molecular dynamics simulations were conducted to investigate the time evolution of microscopic damage in polyetheretherketone (PEEK) polymers under cyclic loading conditions. Three characteristics were used to quantify microscopic damage: entropy, distribution of the end-to-end distance of polymers, and the volume fraction of voids. Our results show that the degree of disentanglement of polymers and the volume fraction of voids increase with cyclic loading, which may lead to entropy generation. Uniaxial tensile strength simulations of the polymer system before and after cyclic loading were performed. The tensile strength after cyclic loading was lower than that before loading. Furthermore, two systems with the same entropy and different loading histories showed almost the same strength. These results imply that entropy generation is expressed as the total microscopic damage and can potentially be employed for effective evaluation of the degradation of material characteristics.

Elevated Strain Rate Characterization of Compression Molded Direct/In-Line Compounded Carbon Fibre/Polyamide 66 Long Fibre Thermoplastic

Compression molded direct compounded carbon fibre D-LFT was evaluated at quasi-static strain rates through uniaxial tension tests (including a specimen size study) and a variation of the ISO 6603-2 puncture test. No significant size effects were observed for the modulus or strength obtained from tensile specimens with four gauge lengths (6.25 mm to 57 mm). Failure strain decreased by 27.5%/29.9%, respectively, across the gauge length range for the 0°/90° directions. Intermediate strain rate (10 s^-1 to 200 s^-1) characterization was completed through uniaxial tension tests on a novel apparatus and ISO 6603-2 puncture tests. Intermediate rate tensile tests showed minimal rate sensitivity for the 0°/90° directions. Initial stiffness was 50% higher for ISO 6603-2 impact tests compared to quasi-static tests. Displacement at the onset of fracture was 95% lower for impact tests compared to quasi-static loading. The peak force/displacement at peak force were reduced for impact tests (21% and 20%, respectively) compared to quasi-static testing.

On the Mode I and Mode II Delamination Characteristics and Surface Morphological Aspects of Composites with Carbon-Thermoplastic Hybrid Fabrics and Innovative Liquid Thermoplastic Resin

In the current research, the delamination behavior under Mode I and Mode II loading for the hybrid carbon-thermoplastic fabrics in conjunction with novel liquid thermoplastic acrylic Elium^® resin processable at ambient conditions was studied. The experimentation by incorporating doublers methodology, studying the performance under Mode I and Mode II loading, and understanding failure mechanisms using surface morphological fractography is deliberated. Hybrid Carbon-Ultra-high molecular weight polyethylene (UHMWPP)/Elium^® composite has shown a 22.81% higher G_IC and a 22.2% higher G_IIC than Carbon-UHMWPP/Epoxy composite. On the contrary, the Carbon_Ultra-high molecular weight polypropylene (UHMWPE)/Elium^® has shown an 11.11% higher Mode I critical energy release rate (G_IC) and a 7.58% higher Mode II critical energy release rate (G_IIC) than Carbon_UHMWPE/Epoxy composite. Hybrid fiber reinforced thermoplastic composites have shown severe plastic deformation of the matrix, rough fracture surface, and micro-cracks on the de-bonding surface, extensive fiber bridging, and crack branching which contributed to the improvement in the delamination behavior. Hybrid fiber architecture is also found to be detrimental by inducing crack arresting mechanisms including the tortuous crack path and the resin-rich pockets path due to the mismatch of the size of the fiber yarns.

Effects of the Pre-Consolidated Materials Manufacturing Method on the Mechanical Properties of Pultruded Thermoplastic Composites

The choice of a manufacturing process, raw materials, and process parameters affects the quality of produced pre-consolidated tapes used in thermoplastic pultrusion. In this study, we used two types of pre-consolidated GF/PP tapes—commercially available (ApATeCh-Tape Company, Moscow, Russia) and inhouse-made tapes produced from commingled yarns (Jushi Holdings Inc., Boca Raton, FL, USA)—to produce pultruded thermoplastic Ø 6 mm bars and 75 mm × 3.5 mm flat laminates. Flat laminates produced from inhouse-made pre-consolidated tapes demonstrated higher flexural, tensile, and apparent interlaminar shear strength compared to laminates produced from commercial pre-consolidated tapes by as much as 106%, 6.4%, and 27.6%, respectively. Differences in pre-consolidated tape manufacturing methods determine the differences in glass fiber impregnation and, thus, differences in the mechanical properties of corresponding pultruded composites. The use of commingled yarns (consisting of matrix and glass fibers properly intermingled over the whole length of prepreg material) makes it possible to achieve a more uniform impregnation of inhouse-made pre-consolidated tapes and to prevent formation of un-impregnated regions and matrix cracks within the center portion of the fiber bundles, which were observed in the case of commercial pre-consolidated tapes. The proposed method of producing pre-consolidated tapes made it possible to obtain pultruded composite laminates with larger cross sections than their counterparts described in the literature, featuring better mechanical properties compared to those produced from commercial pre-consolidated tapes.

Research Progress of Wood-Based Panels Made of Thermoplastics as Wood Adhesives

When thermoplastic resins such as polyethylene (PE) and polypropylene (PP) are selected as wood adhesives to bond wood particles (fibers, chips, veneers) by using the hot-pressing technique, the formaldehyde emission issue that has long existed in the wood-based panel industry can be effectively solved. In this study, in general, thermoplastic-bonded wood-based panels presented relatively higher mechanical properties and better water resistance and machinability than the conventional urea-formaldehyde resin-bonded wood-based panels. However, the bonding structure of the wood and thermoplastic materials was unstable at high temperatures. Compared with the wood-plastic composites manufactured by the extruding or injection molding methods, thermoplastic-bonded wood-based panels have the advantages of larger size, a wider raw material range and higher production efficiency. The processing technology, bonding mechanism and the performance of thermoplastic-bonded wood-based panels are comprehensively summarized and reviewed in this paper. Meanwhile, the existing problems of this new kind of panel and their future development trends are also highlighted, which can provide the wood industry with foundations and guidelines for using thermoplastics as environmentally friendly adhesives and effectively solving indoor pollution problems.

Optimizing Bladder Resin Transfer Molding Process to Manufacture Complex, Thin-Ply Thermoplastic Tubular Composite Structures: An Experimental Case Study

The bladder molding process is primarily used in sporting applications but mostly with prepregs. Bladder-Assisted Resin Transfer Molding (B-RTM) presents the tremendous potential to automate and mass produce the complex hollow-composite profiles. Thin-ply, non-crimp fabrics (NCFs) provide excellent mechanical, fracture toughness, and vibration damping properties on top of the weight saving it offers to a final product. However, these fiber architectures are difficult to inject due to the resistance they provide for the polymer flow using the liquid injection process. Therefore, it is mandatory to optimize the process parameters to reduce the time for injection and simultaneously achieve better consolidation. This work presents a first, detailed, experimental case study to successfully inject a low-permeability, thin-ply, complex, thermoplastic tubular structure, and the effect of process parameters, boundary conditions, the associated manufacturing challenges, and proposed solutions are deliberated in this paper.

Fabrication: Mechanical Testing and Structural Simulation of Regenerated Cellulose Fabric Elium® Thermoplastic Composite System

Regenerated cellulose fibres are an important part of the forest industry, and they can be used in the form of fabrics as reinforcement materials. Similar to the natural fibres (NFs), such as flax, hemp and jute, that are widely used in the automotive industry, these fibres possess good potential to be used for semi-structural applications. In this work, the mechanical properties of regenerated cellulose fabric-reinforced poly methyl methacrylate (PMMA) (Elium^®) composite were investigated and compared with those of its natural fibre composite counterparts. The developed composite demonstrated higher tensile strength and ductility, as well as comparable flexural properties with those of NF-reinforced epoxy and Elium^® composite systems, whereas the Young’s modulus was lower. The glass transition temperature demonstrated a value competitive (107.7 °C) with that of other NF composites. Then, the behavior of the bio-composite under bending and loading was simulated, and a materials model was used to simulate the behavior of a car door panel in a flexural scenario. Modelling can contribute to predicting the structural behavior of the bio-based thermoplastic composite for secondary applications, which is the aim of this work. Finite element simulations were performed to assess the deflection and force transfer mechanism for the car door interior.

Comprehensive Review of the Properties and Modifications of Carbon Fiber-Reinforced Thermoplastic Composites

Carbon fiber-reinforced polymers are considered a promising composite for many industrial applications including in the automation, renewable energy, and aerospace industries. They exhibit exceptional properties such as a high strength-to-weight ratio and high wear resistance and stiffness, which give them an advantage over other conventional materials such as metals. Various polymers can be used as matrices such as thermosetting, thermoplastic, and elastomers polymers. This comprehensive review focuses on carbon fiber-reinforced thermoplastic polymers due to the advantages of thermoplastic compared to thermosetting and elastomer polymers. These advantages include recyclability, ease of processability, flexibility, and shorter production time. The related properties such as strength, modulus, thermal conductivity, and stability, as well as electrical conductivity, are discussed in depth. Additionally, the modification techniques of the surface of carbon fiber, including the chemical and physical methods, are thoroughly explored. Overall, this review represents and summarizes the future prospective and research developments carried out on carbon fiber-reinforced thermoplastic polymers.

Review: Filament Winding and Automated Fiber Placement with In Situ Consolidation for Fiber Reinforced Thermoplastic Polymer Composites

Fiber reinforced thermoplastic composites are gaining popularity in many industries due to their short consolidation cycles, among other advantages over thermoset-based composites. Computer aided manufacturing processes, such as filament winding and automated fiber placement, have been used conventionally for thermoset-based composites. The automated processes can be adapted to include in situ consolidation for the fabrication of thermoplastic-based composites. In this paper, a detailed literature review on the factors affecting the in situ consolidation process is presented. The models used to study the various aspects of the in situ consolidation process are discussed. The processing parameters that gave good consolidation results in past studies are compiled and highlighted. The parameters can be used as reference points for future studies to further improve the automated manufacturing processes.

Performance of Short Fiber Interlayered Reinforcement Thermoplastic Resin in Additive Manufacturing

To further improve the mechanical properties of thermoplastic resin in additive manufacturing (AM), this paper presents a novel method to directly and quantitatively place the short fibers (SFs) between two printing process of resin layers. The printed composite parts with SFs between the layers was reinforced. The effects of single-layer fiber content, multi-layer fiber content and the length of fibers on the mechanical properties of printed specimens were studied. The distribution of fibers and quality of interlayer bonding were assessed using mechanical property testing and microstructure examination. The results showed that the tensile strength of the single-layered specimen with 0.5 wt% interlayered SFs increased by 18.82%. However, when the content of SFs continued to increase, the mechanical properties declined because of the increasing interlayered gap and the poor bonding quality. In addition, when the interlayered SFs length was 0.5-1 mm, the best reinforcement was obtained. To improve the interfacial bonding quality between the fiber and the resin, post-treatment and laser-assisted preheating printing was used. This method is effective for the enhancement of the interfacial bonding to obtain better mechanical properties. The research proves that adding SFs by placement can reduce the wear and breakage of the fibers compared to the conventional forming process. Therefore, the precise control of the length and content of SFs was realized in the specimen. In summary, SFs placement combined with post-treatment and laser-assisted preheating is a new method in AM to improve the performance of thermoplastic resin.

Ultrasonic Welding of Novel Carbon/ Elium® Thermoplastic Composites with Flat and Integrated Energy Directors: Lap Shear Characterisation and Fractographic Investigation

The current research work presents a first attempt to investigate the welding attributes of Elium^® thermoplastic resin and the fusion bonding using ultrafast ultrasonic welding technique. The integrated energy director (ED) polymer-matrix composites (PMCs) panel manufacturing was carried out using the Resin Transfer Moulding (RTM) technique and the scheme is deduced to manufacture a bubble-free panel. Integrated ED configurations and flat specimens with Elium^® film of different thickness at the interface were investigated for ultrasonic welding optimization. Optimised weld time for integrated ED and flat Elium^® panels with film (0.5 mm thick) configuration was found to be 1 s and 5.5 s, respectively. The ED integrated configuration showed the best welding results with a lap shear strength of 18.68 MPa. The morphological assessment has shown significant plastic deformation of Elium^® resin and the shear cusps formation, which enhances the welding strength. This research has the potential to open up an excellent and automated way of joining Elium^® composite parts in automotive, wind turbines, sports, and many other industrial applications.

Investigation on Ultrasonic Welding Attributes of Novel Carbon/Elium® Composites

Joining large and complex polymer–matrix composite structures is becoming increasingly important in industries such as automobiles, aerospace, sports, wind turbines, and others. Ultrasonic welding is an ultra-fast joining process and also provides excellent joint quality as a cost-effective alternative to other joining processes. This research aims at investigating the welding characteristics of novel methyl methacrylate Elium^®, a liquid thermoplastic resin. Elium^® is the first of its kind of thermoplastic resin, which is curable at room temperature and is suitable for mass production processes. The welding characteristics of Elium^® composites were investigated by optimizing the welding parameters with specially designed integrated energy directors (ED) and manufactured using the Resin transfer molding process. The results showed a 23% higher lap shear strength for ultrasonically welded composite joints when compared to the adhesively bonded joints. The optimized welding time for the ultrasonic welded joint was found to be 1.5 s whereas it was 10 min for the adhesively bonded joint. Fractographic analysis showed the significant plastic deformation and shear cusps formation on the fractured surface, which are typical characteristics for strong interfacial bonding.

Fabrication of In Situ Nanofiber-Reinforced Molecular Composites by Nonequilibrium Self-Assembly

Although the concept of molecular composites (MCs) is very promising, there are major obstacles arising from the immiscibility of the rigid-rod with the random-coil polymers. Here, we developed a novel method for fabricating an in situ reinforced MC system with nonequilibrium self-assembled nanofibrous structures based on bisphenol A epoxy resin, 4,4'-diaminodiphenylsulfone, bismaleimide, and a polyphenylene ether (PPO) oligomer. A variety of spectroscopic and morphological techniques were used to probe the structural evolution from the emergence of nanofibrils, to growth and aggregation of nanofibers, and then to the formation of in situ reinforced MC with strong interfacial interactions. The in situ nanofibers within the polymer matrix could be formed by the polymerization force extruding the PPO phase through the interspaces within the simultaneous interpenetrating network polymers during the cure process of the thermosetting resin system. Compared to the control sample, the in situ nanofiber-reinforced MC exhibited better thermal properties and flame retardancy. In particular, the obtained MC showed a significant improvement in glass transition temperature and mechanical properties, which were mainly attributed to the restriction of high thermal stability of PPO on the segmental motion of polymer chains, the toughening and reinforcement behaviors of PPO nanofibers on the matrix, and the chemical interaction at the PPO/matrix interface.

A comparison of the fitting accuracy of thermoplastic denture base resins used in non-metal clasp dentures to a conventional heat-cured acrylic resin

OBJECTIVE

To incorporate a metal framework into removable partial dentures, the dimensional accuracy of thermoplastic resins requires precision equivalent to conventional acrylic resins. This study aimed to evaluate the fitting accuracy of thermoplastic resins compared to heat-cured acrylic resin.

MATERIALS AND METHODS

Four thermoplastic resins (polyethylene terephthalate [EstheShot, ES; EstheShot Bright, ES-B], polyamide [Lucitone FRS, LF], polycarbonate [Reigning Resin N, RN] and a heat-curing acrylic resin [Acron, AC]) were used. The specimens were created on master casts constructed of high-strength stone that simulated a maxillary edentulous ridge. Additionally, high-expansion stone was used as the master cast for RN specimens. The ES-B, LF and RN specimens were prepared with and without annealing after injection molding. The gaps between the molded resin and the cast were measured.

RESULTS

ES had the smallest gap and was significantly smaller than AC (p < 0.05). The gap sizes of ES-B, LF and RN (high-expansion stone) without annealing were similar to AC (p > 0.05), while the gap size of RN (high-strength stone) with and without annealing was significantly greater than AC (p < 0.001). The gap sizes of ES-B and LF with annealing were significantly less than AC (p < 0.05). Further, the gap sizes of ES-B, LF and RN with annealing were significantly smaller than the gaps without annealing (p < 0.05).

CONCLUSIONS

The results suggested that ES, ES-B and LF have adequate fitting accuracy for incorporating metal framework into dentures and that annealing effectively improved the fitting accuracy of ES-B, LF and RN.