The role of material characterisation in the crush modelling of thermoplastic composite structures

The predictive capability of high fidelity finite element modelling, to accurately capture damage and crush behaviour of composite structures, relies on the acquisition of accurate material properties, some of which have necessitated the development of novel approaches. This paper details the measurement of interlaminar and intralaminar fracture toughness, the non-linear shear behaviour of carbon fibre (AS4)/thermoplastic Polyetherketoneketone (PEKK) composite laminates and the utilisation of these properties for the accurate computational modelling of crush. Double-cantilever-beam (DCB), four-point end-notched flexure (4ENF) and Mixed-mode bending (MMB) test configurations were used to determine the initiation and propagation fracture toughness in mode I, mode II and mixed-mode loading, respectively. Compact Tension (CT) and Compact Compression (CC) test samples were employed to determine the intralaminar longitudinal tensile and compressive fracture toughness. V-notched rail shear tests were used to measure the highly non-linear shear behaviour, associated with thermoplastic composites, and fracture toughness. Corresponding numerical models of these tests were developed for verification and yielded good correlation with the experimental response. This also confirmed the accuracy of the measured values which were then employed as input material parameters for modelling the crush behaviour of a corrugated test specimen.

Mechanochemical Synthesis of Pharmaceutical Cocrystal Suspensions via Hot Melt Extrusion: Feasibility Studies and Physicochemical Characterisation

Engineered cocrystals offer an alternative solid drug form with tailored physicochemical properties. Interestingly, although cocrystals provide many new possibilities, they also present new challenges, particularly in regard to their design and large-scale manufacture. Current literature has primarily focused on the preparation and characterization of novel cocrystals typically containing only the drug and coformer, leaving the subsequent formulation less explored. In this paper we propose, for the first time, the use of hot melt extrusion for the mechanochemical synthesis of pharmaceutical cocrystals in the presence of a meltable binder. In this approach, we examine excipients that are amenable to hot melt extrusion, forming a suspension of cocrystal particulates embedded in a pharmaceutical matrix. Using ibuprofen and isonicotinamide as a model cocrystal reagent pair, formulations extruded with a small molecular matrix carrier (xylitol) were examined to be intimate mixtures wherein the newly formed cocrystal particulates were physically suspended in a matrix. With respect to formulations extruded using polymeric carriers (Soluplus and Eudragit EPO, respectively), however, there was no evidence within PXRD patterns of either crystalline ibuprofen or the cocrystal. Importantly, it was established in this study that an appropriate carrier for a cocrystal reagent pair during HME processing should satisfy certain criteria including limited interaction with parent reagents and cocrystal product, processing temperature sufficiently lower than the onset of cocrystal Tm, low melt viscosity, and rapid solidification upon cooling.

Modelling the crush behaviour of thermoplastic composites

Thermoplastic composites are likely to emerge as the preferred solution for meeting the high-volume production demands of passenger road vehicles. Substantial effort is currently being directed towards the development of new modelling techniques to reduce the extent of costly and time consuming physical testing. Developing a high-fidelity numerical model to predict the crush behaviour of composite laminates is dependent on the accurate measurement of material properties as well as a thorough understanding of damage mechanisms associated with crush events. This paper details the manufacture, testing and modelling of self-supporting corrugated-shaped thermoplastic composite specimens for crashworthiness assessment. These specimens demonstrated a 57.3% higher specific energy absorption compared to identical specimen made from thermoset composites. The corresponding damage mechanisms were investigated in-situ using digital microscopy and post analysed using Scanning Electron Microscopy (SEM). Splaying and fragmentation modes were the 2 primary failure modes involving fibre breakage, matrix cracking and delamination. A mesoscale composite damage model, with new non-linear shear constitutive laws, which combines a range of novel techniques to accurately capture the material response under crushing, is presented. The force-displacement curves, damage parameter maps and dissipated energy, obtained from the numerical analysis, are shown to be in a good qualitative and quantitative agreement with experimental results. The proposed approach could significantly reduce the extent of physical testing required in the development of crashworthy structures.  

Activated lignin‒chitosan extruded blends for efficient adsorption of methylene blue

This work investigates the production of activated lignin-chitosan extruded (ALiCE) pellets with controlled particle size distribution (almost spherical: dp ~500‒1000µm) for efficient methylene blue adsorption. The novel preparation method employed in this study successfully produced activated lignin-chitosan pellets. Structural and morphological characterizations were performed using BET, FTIR and SEM-EDX analyses. The influence of contact time, solution pH, ionic strength, initial adsorbate concentration and desorption studies was investigated. The experimental data fitted well with the Langmuir isotherm (R2 = 0.997), yielding a maximum adsorption capacity of 36.25mg/g. The kinetic data indicated that methylene blue (MB) adsorption onto ALiCE can be represented by the pseudo second-order-model with intraparticle processes initially controlling the process of MB adsorption. Overall, these results indicate that the novel ALiCE offers great potential for removing cationic organic pollutants from rivers and streams.

The use of binary polymeric networks in stabilising polyethylene oxide solid dispersions

The objective of this study was to determine if a high Tg polymer (Eudragit® S100) could be used to stabilize amorphous domains of polyethylene oxide (PEO) and hence improve the stability of binary polymer systems containing celecoxib (CX). We propose a novel method of stabilizing the amorphous PEO solid dispersion through inclusion of a miscible, high Tg polymer, namely, that can form strong inter-polymer interactions. The effects of inter-polymer interactions and miscibility between PEO and Eudragit S100 are considered. Polymer blends were first manufactured via hot-melt extrusion at different PEO/S100 ratios (70/30, 50/50, and 30/70 wt/wt). Differential scanning calorimetry and dynamic mechanical thermal analysis data suggested a good miscibility between PEO and S100 polymer blends, particularly at the 50/50 ratio. To further evaluate the system, CX/PEO/S100 ternary mixtures were extruded. Immediately after hot-melt extrusion, a single Tg that increased with increasing S100 content (anti-plasticization) was observed in all ternary systems. The absence of powder X-ray diffractometry crystalline Bragg’s peaks also suggested amorphization of CX. Upon storage (40°C/75% relative humidity), the formulation containing PEO/S100 at a ratio of 50:50 was shown to be most stable. Fourier transform infrared studies confirmed the presence of hydrogen bonding between Eudragit S100 and PEO suggesting this was the principle reason for stabilization of the amorphous CX/PEO solid dispersion system.