Development of a new pultrusion equipment to manufacture thermoplastic matrix composite profiles

This paper describes the design and manufacture of a low-cost full scale pultrusion prototype equipment and discusses the production and obtained mechanical properties of polypropylene/glass (GF/PP) reinforced composite ba rs fabricated by using the prototype equipment. Three different GF/PP pre-impregnated ra w-materials, a commercial GF/PP comingled system from Vetrotex, a GF/PP powder coat ed towpreg [1-3] and, a GF/PP pre- consolidated tape (PCT) produced in our laboratorie s, were used in the production of composite bars that were subsequently submitted to mechanical testing in order to determine the relevant mechanical properties and quantify the consolidation quality. Samples of the different composite profiles were also observed und er SEM microscopy.

Filament wound products made with thermoplastic matrix towpregs

Cost-effective glass-reinforced thermoplastic matri x towpregs produced by a powder coating line were used to manufacture composite pipes by fi lament winding. A conventional 6 axes filament-winding equipment was adapted for processi ng such structures. The influence of the filament winding speed and mandrel temperature on t he composite final properties was studied in the present work. An optimized processin g window was established by comparing the composite theoretical expected mechanical prope rties with the experimentally obtained ones. The final properties determined on the produc ed pipes and structures and the technological changes introduced to the conventiona l filament-winding equipment will be presented and discussed. Besides the processing des cription and conditions, it will be presented the relationship between processing condi tions and mechanical properties.

Mechanical characterization of polyhydroxyalkanoate and poly (lactic acid) blends

In this work, the mechanical behavior of polyhyroxyalkanoate (PHA)/poly(lactic acid) (PLA) blends is investigated in a wide range of compositions. The mechanical properties can be optimized by varying the PHA contents of the blend. The flexural and tensile properties were estimated by different models: the rule of mixtures, Kerner–Uemura–Takayanagi (KUT) model, Nicolai–Narkis model and Béla–Pukánsky model. This study was aimed at investigating the adhesion between the two material phases. The results anticipate a good adhesion between both phases. Nevertheless, for low levels of incorporation of PHA (up to 30%), where PLA is expectantly the matrix, the experimental data seem to deviate from the perfect adhesion models, suggesting a decrease in the adhesion between both polymeric phases when PHA is the disperse phase. For the tensile modulus, a linear relationship is found, following the rules of mixtures (or a KUT model with perfect adhesion between phases) denoting a good adhesion between the phases over the composition range. The incorporation of PHA in the blend leads to a decrease in the flexural modulus but, at the same time, increases the tensile modulus. The impact energy of the blends varies more than 157% over the entire composition. For blends with PHA weight fraction lower than 50%, the impact strength of the blend is higher than the pure base polymers. The highest synergetic effect is found when the PLA is the matrix and the PHA is the disperse phase for the blend PHA/PLA of 30/70. The second maximum is found for the inverse composition of 70/30. PLA has a heat-deflection temperature (HDT) substantially lower than PHA. For the blends, the HDT increases with the increment in the percentage of the incorporation of PHA. With up to 50% PHA (PLA as matrix), the HDT is practically constant and equal to PLA value. Above this point (PHA matrix), the HDT of the polymer blends increases linearly with the percentage of addition of PHA.

Processing of continuous fibre reinforced thermoplastics

Towpregs based on different fibres and thermoplastic matrices were processed for highly demanding and more commercial applications by different composite processing technologies. In the technologies used, compression moulding and pultrusion, the final composite pr ocessing parameters were studied in order to obtain composites with adequate properties at industrial compatible production rates. The produced towpregs were tested to verify its polymer content and degree of impregnation. The obtained results have shown t hat the coating line enabled to produce, with efficiency and industrial scale speed rates, thermoplastic matrix towpregs that may be used to manufacture composites for advanced and larger volume commercial markets.

Experimental study on polyester based concretes filled with glass fibre reinforced plastic recyclates – a contribution to composite materials sustainability

The development and applications of thermoset polymeric composites, namely fibre reinforced plastics (FRP), have shifted in the last decades more and more into the mass market [1]. Despite of all advantages associated to FRP based products, the increasing production and consume also lead to an increasing amount of FRP wastes, either end-of-lifecycle products, or scrap and by-products generated by the manufacturing process itself. Whereas thermoplastic FRPs can be easily recycled, by remelting and remoulding, recyclability of thermosetting FRPs constitutes a more difficult task due to cross-linked nature of resin matrix. To date, most of the thermoset based FRP waste is being incinerated or landfilled, leading to negative environmental impacts and supplementary added costs to FRP producers and suppliers. This actual framework is putting increasing pressure on the industry to address the options available for FRP waste management, being an important driver for applied research undertaken cost efficient recycling methods. [1-2]. In spite of this, research on recycling solutions for thermoset composites is still at an elementary stage. Thermal and/or chemical recycling processes, with partial fibre recovering, have been investigated mostly for carbon fibre reinforced plastics (CFRP) due to inherent value of carbon fibre reinforcement; whereas for glass fibre reinforced plastics (GFRP), mechanical recycling, by means of milling and grinding processes, has been considered a more viable recycling method [1-2]. Though, at the moment, few solutions in the reuse of mechanically-recycled GFRP composites into valueadded products are being explored. Aiming filling this gap, in this study, a new waste management solution for thermoset GFRP based products was assessed. The mechanical recycling approach, with reduction of GFRP waste to powdered and fibrous materials was applied, and the potential added value of obtained recyclates was experimentally investigated as raw material for polyester based mortars. The use of a cementless concrete as host material for GFRP recyclates, instead of a conventional Portland cement based concrete, presents an important asset in avoiding the eventual incompatibility problems arisen from alkalis silica reaction between glass fibres and cementious binder matrix. Additionally, due to hermetic nature of resin binder, polymer based concretes present greater ability for incorporating recycled waste products [3]. Under this scope, different GFRP waste admixed polymer mortar (PM) formulations were analyzed varying the size grading and content of GFRP powder and fibre mix waste. Added value of potential recycling solution was assessed by means of flexural and compressive loading capacities of modified mortars with regard to waste-free polymer mortars.

A Study on Microstructure Characteristics of TEPs-modified Adhesives

Thermally expandable particles (TEPs) were developed by Dow Chemical Co in the early 1970´s [1] and were further developed by others [2, 3]. They are particles made up of a thermoplastic shell filled with liquid hydrocarbon. On heating them, two transformations will occur. One is the softening of shell material and the other is the gasification of the hydrocarbon liquid inside it. As a consequence, the shell will expand as the gas inside it will push the softened shell from inside out causing it to grow in size [4]. When fully expanded, the growth in volume of the particle can be from 50 to 100 times [3]. Owing to this unique behaviour, TEPs are used by the industry in a wide variety of applications mainly for weight reduction and appearance improvement for thermoplastics, inks, and coatings. In adhesive bonding, TEPs have been used for recycling purposes. Moreover, TEPs might be used to modify structural adhesives for other new purposes, such as: to increase the joint strength by creating an adhesive functionally modified along the overlap of the joint by gradual heating and/or to heal the adhesive in case of damage.

Estudo da Produção de Towpregs e Transformação por Pultrusão

Durante as últimas décadas, os materiais compósitos têm substituído com sucesso os materiais tradicionais em muitas aplicações de engenharia, muito devido às excelentes propriedades que se conseguem obter com a combinação de materiais diferentes. Nos compósitos reforçados com fibras longas ou contínuas tem-se verificado, ao longo dos últimos anos, um aumento do uso de matrizes termoplásticas, fruto de várias vantagens associadas, como o facto de serem bastante mais ecológicas, comparativamente às termoendurecíveis. No entanto, este aumento está muito dependente do desenvolvimento de novas tecnologias de processamento, pois a elevada viscosidade dos termoplásticos, comparativamente aos termoendurecíveis, dificulta significativamente o processo. Muitos equipamentos de produção de termoplásticos são resultado de adaptações de equipamentos de produção de termoendurecíveis, onde normalmente é necessário adicionar fornos de pré-aquecimento. Neste trabalho, pretendeu-se produzir pré-impregnados de fibras contínuas com matriz termoplástica, por deposição a seco de polímero em pó sobre fibras de reforço (denominados por towpreg) para, posteriormente, serem transformados por pultrusão e caracterizados. As matérias-primas utilizadas foram: Polipropileno (PP) como matriz termoplástica e fibra de carbono como reforço. Por forma a melhorar as propriedades finais do compósito, foram otimizadas as condições de processamento na produção dos towpregs, estudando-se a influência da variação dos parâmetros de processamento no teor de polímero presente nestes, tendo como objetivo teores mássicos de polímero superiores a 30%. A condição ótima e a influência dos parâmetros de processamento foram obtidas com o auxílio do Método de Taguchi. Os perfis produzidos por pultrusão foram sujeitos a ensaios de flexão, de forma a obter as suas propriedades quando sujeitos a esse tipo de esforço. Foram também realizados ensaios de calcinação de forma a obter as frações mássicas de fibra e polímero presentes no compósito final. Sabidas as frações mássicas, converteramse em frações volúmicas e obtiveram-se as propriedades teoricamente esperadas através da Lei das Misturas e compararam-se com as obtidas experimentalmente. As propriedades obtidas foram também comparadas com as de outros compósitos pultrudidos.