Advanced Composites Manufacturing and Plastics Processing

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20 pages, 5333 KiB

Open AccessArticle

Designing Prepregnation and Fused Filament Fabrication Parameters for Recycled PP- and PA-Based Continuous Carbon Fiber Composites

by Marah Baddour, Ruth Garcia-Campà, Pablo Reyes, Dagmar R. D’hooge, Ludwig Cardon and Mariya Edeleva

Materials 2024, 17(8), 1788; https://doi.org/10.3390/ma17081788 - 12 Apr 2024

Viewed by 562

Abstract

Continuous carbon fiber (cCF)-based 3D-printed polymer composites are known for their excellent flexural properties; however, the optimization of the overall process is still desired, depending on the material types involved. Here, the improved manufacturing of cCF-based composites is reported, considering virgin polyamide (PA) and postindustrial waste polypropylene (PP), and the parameters affecting the material properties are evaluated. Firstly, the prepregnation technique was optimized to manufacture cCF polymer filaments with various fiber-to-polymer ratios. Secondly, the fused filament fabrication (FFF) technique was optimized. It was observed that the layer height needs to be sufficiently low for proper interlayer adhesion. The influence of the printing temperature is more complicated, with filaments characterized by a lower fiber-to-polymer ratio requiring a higher nozzle diameter and higher temperatures for efficient printing; and for lower diameters, the best flexural properties are observed for parts printed at lower temperatures, maintaining a high interspace distance. Plasma treatment of the cCF was also explored, as was annealing of the produced parts to enhance the flexural properties, the latter being specifically interesting for the PP-based composite due to a lower wetting caused by a higher viscosity, despite supportive interfacial interactions. Eventually, overall guidelines were formulated for the successful production of cCF-based composites. Full article

(This article belongs to the Topic Advanced Composites Manufacturing and Plastics Processing)

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20 pages, 4793 KiB

Open AccessArticle

A Comprehensive Study on the Optimization of Drilling Performance in Hybrid Nano-Composites and Neat CFRP Composites Using Statistical and Machine Learning Approaches

by Tanzila Nargis, S. M. Shahabaz, Subash Acharya, Nagaraja Shetty, Rashmi Laxmikant Malghan and S. Divakara Shetty

J. Manuf. Mater. Process. 2024, 8(2), 67; https://doi.org/10.3390/jmmp8020067 - 29 Mar 2024

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Abstract

Carbon fiber-reinforced polymer (CFRP) composites have gradually replaced metals due to their exceptional strength-to-weight ratio compared to metallic materials. However, the drilling process often reveals various defects, such as surface roughness, influenced by different drilling parameters. This study explores the drilling quality of uni-directional CFRP composites, as well as hybrid Al₂O₃ alumina and hybrid SiC silicon carbide nano-composites, through experimental exploration using step, core, and twist drills. Response surface methodology (RSM) and statistical tools, including main effect plots, ANOVA, contour plots, and optimization techniques, were used to analyze the surface roughness of the hole. Optimization plots were drawn for optimal conditions, suggesting a spindle speed of 1500 rpm, feed of 0.01 mm/rev, and a 4 mm drill diameter for achieving minimum surface roughness. Furthermore, two machine learning models, artificial neural network (ANN) and random forest (RF), were used for predictive analysis. The findings revealed the robust predictive capabilities of both models, with RF demonstrating superior performance over ANN and RSM. Through visual comparisons and error analyses, more insights were gained into model accuracy and potential avenues for improvement. Full article

(This article belongs to the Topic Advanced Composites Manufacturing and Plastics Processing)

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15 pages, 11314 KiB

Open AccessArticle

The Impact of PP-g-MAH on Mechanical Properties of Injection Molding of Long Glass Fiber/Polypropylene Pellets from Thermoplastic Pultrusion Process

by Ponlapath Tipboonsri and Anin Memon

J. Manuf. Mater. Process. 2024, 8(2), 53; https://doi.org/10.3390/jmmp8020053 - 02 Mar 2024

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Abstract

Long fiber thermoplastic pellets are pellets containing discontinuous reinforced fibers and a matrix, offering excellent mechanical properties, good processability, recyclability, and low cost. Typically, commercial LFTP is manufactured through the hot melt impregnation process, combining extrusion and pultrusion. Although there is a thermoplastic pultrusion process for LFTP production, characterized by a simple machine and an easy method, its mechanical properties have not yet approached those of commercial LFTP. In improving the mechanical characteristics of LFTP manufactured via thermoplastic pultrusion, this research employed polypropylene-graft-maleic anhydride as a coupling agent during the injection molding procedure. The LFTP is composed of polypropylene material reinforced with glass fiber. Mechanical and physical properties of the LFTP were investigated by introducing PP-g-MAH at concentrations of 4, 8, and 12 wt% through injection molding. The results revealed that, at a 4 wt% concentration of PP-g-MAH, the LFTP composites exhibited heightened tensile, flexural and impact strengths. However, these properties began to decrease upon exceeding 4 wt% PP-g-MAH. The enhanced interfacial adhesion among glass fibers, induced by PP-g-MAH, contributed to this improvement. Nonetheless, excessive amounts of PP-g-MAH led to a reduction in molecular weight, subsequently diminishing the impact strength, tensile modulus, and flexural modulus. In LFTP composites, both tensile and flexural strengths exhibited a positive correlation with the PP-g-MAH concentration, attributed to improved interfacial adhesion between glass fibers and polypropylene, coupled with a reduction in fiber pull-out. Based on morphological analysis by SEM, the incorporation of PP-g-MAH improved interfacial bonding and decreased fiber pull-out. The presence of maleic anhydride in the LFTPc was confirmed through the utilization of FTIR spectroscopy. Mechanical properties of LFTP containing 4 wt% PP-g-MAH were found to be equivalent to or superior to those of commercial LFTP, according to the results of a comparative analysis. Full article

(This article belongs to the Topic Advanced Composites Manufacturing and Plastics Processing)

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0 pages, 5079 KiB

Open AccessArticle

Machinability and Surface Properties of Cryogenic Poly(methyl methacrylate) Machined via Single-Point Diamond Turning

by Xiaoyu Wu, Qiang Kang, Xiaoxing Jiang and Xudong Fang

Materials 2024, 17(4), 866; https://doi.org/10.3390/ma17040866 - 13 Feb 2024

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Abstract

Poly(methyl methacrylate) (PMMA), with a glass transition temperature (Tg) over 100 °C, shows good mechanical and optical properties and has broad applications after being machined with single-point diamond turning (SPDT) at room temperature. Because of the high Tg, current efforts mostly focus on optimizing machining parameters to improve workpiece precision without considering the modification of material properties. Cryogenic cooling has been proven to be an effective method in assisting ultra-precision machining for certain types of metals, alloys, and polymers, but has never been used for PMMA before. In this work, cryogenic cooling was attempted during the SPDT of PMMA workpieces to improve surface quality. The machinability and surface properties of cryogenically cooled PMMA were investigated based on the mechanical properties at corresponding temperatures. Nanoindentation tests show that, when temperature is changed from 25 °C to 0 °C, the hardness and Young’s modulus are increased by 37% and 22%, respectively. At these two temperature points, optimal parameters including spindle speed, feed rate and cut depth were obtained using Taguchi methods to obtain workpieces with high surface quality. The surface quality was evaluated based on the total height of the profile (Pt) and the arithmetic mean deviation (Ra). The measurement results show that the values of Pt and Ra of the workpiece machined at 0 °C are 124 nm and 6 nm, respectively, while the corresponding values of that machined at 25 °C are 291 nm and 11 nm. The test data show that cryogenic machining is useful for improving the form accuracy and reducing the surface roughness of PMMA. Moreover, the relationship between temperature, material properties and machinability weas established with dynamic mechanical analysis (DMA) data and a theoretical model. This can explain the origin of the better surface quality of the cryogenic material. The basis of this is that temperature affects the viscoelasticity of the polymer and the corresponding mechanical properties due to relaxation. Then, the material property changes will affect surface profile formation during machining. The experimental results and theoretical analysis show that cryogenically cooled PMMA has good machinability and improved surface quality when using SPDT compared to that at ambient temperature. Full article

(This article belongs to the Topic Advanced Composites Manufacturing and Plastics Processing)

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23 pages, 10146 KiB

Open AccessArticle

Experimental Characterization of Screw-Extruded Carbon Fibre-Reinforced Polyamide: Design for Aeronautical Mould Preforms with Multiphysics Computational Guidance

by Juan Carlos Antolin-Urbaneja, Haritz Vallejo Artola, Eduard Bellvert Rios, Jorge Gayoso Lopez, Jose Ignacio Hernández Vicente and Ana Isabel Luengo Pizarro

J. Manuf. Mater. Process. 2024, 8(1), 34; https://doi.org/10.3390/jmmp8010034 - 09 Feb 2024

Viewed by 1324

Abstract

In this research work, the suitability of short carbon fibre-reinforced polyamide 6 in pellet form for printing an aeronautical mould preform with specific thermomechanical requirements is investigated. This research study is based on an extensive experimental characterization campaign, in which the principal mechanical properties of the printed material are determined. Furthermore, the temperature dependency of the material properties is characterized by testing samples at different temperatures for bead printing and stacking directions. Additionally, the thermal properties of the material are characterized, including the coefficient of thermal expansion. Moreover, the influence of printing machine parameters is evaluated by comparing the obtained tensile moduli and strengths of several manufactured samples at room temperature. The results show that the moduli and strengths can vary from 78% to 112% and from 55% to 87%, respectively. Based on a real case study of its aeronautical use and on the experimental data from the characterization stage, a new mould design is iteratively developed with multiphysics computational guidance, considering 3D printing features and limitations. Specific design drivers are identified from the observed material’s thermomechanical performance. The designed mould, whose mass is reduced around 90% in comparison to that of the original invar design, is numerically proven to fulfil thermal and mechanical requirements with a high performance. Full article

(This article belongs to the Topic Advanced Composites Manufacturing and Plastics Processing)

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15 pages, 2477 KiB

Open AccessArticle

Modeling of a Process Window for Tailored Reinforcements in Overmolding Processes

by Philipp K. W. Picard, Tim A. Osswald, Swen Zaremba and Klaus Drechsler

J. Compos. Sci. 2024, 8(2), 65; https://doi.org/10.3390/jcs8020065 - 08 Feb 2024

Viewed by 964

Abstract

This study explores cost-effective and customized composite applications by strategically placing carbon fiber-reinforced thermoplastics in multi-material designs. The focus is on developing a model for the simultaneous processing of non-reinforced and reinforced thermoplastic layers, with the aim of identifying essential parameters to minimize insert flow and ensure desired fiber orientation and positional integrity. The analysis involves an analytical solution for two layered power-law fluids in a squeeze flow setup, aiming to model the combined flow behavior of Newtonian and pseudo-plastic fluids, highlighting the impact of the non-Newtonian nature. The behavior reveals a non-linear trend in the radial flow ratio towards the logarithmic consistency index ratio compared to a linear trend for Newtonian fluids. While a plateau regime of consistency index ratios presents challenges in flow reduction for both layers, exceeding this ratio, depending on the height ratio of the layers, enables a viable overmolding process. Therefore, attention is required when selectively placing tailored composites with long-fiber-reinforced thermoplastics or unidirectional reinforcements to avoid operating in the plateau region, which can be managed through appropriate cavity or tool designs. Full article

(This article belongs to the Topic Advanced Composites Manufacturing and Plastics Processing)

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18 pages, 8299 KiB

Open AccessArticle

Nanomaterial-Enhanced Sizings: Design and Optimisation of a Pilot-Scale Fibre Sizing Line

by Dionisis Semitekolos, Ioannis Papadopoulos, Stavros Anagnou, Behnam Dashtbozorg, Xiaoying Li, Hanshan Dong and Costas A. Charitidis

Fibers 2024, 12(2), 16; https://doi.org/10.3390/fib12020016 - 04 Feb 2024

Viewed by 1601

Abstract

This study focuses on the development of a pilot-scale sizing line, including its initial design and installation, operational phases, and optimization of key process parameters. The primary objective is the identification of critical parameters for achieving a uniform sizing onto the fibres and the determination of optimal conditions for maximum production efficiency. This investigation focused on adjusting the furnace desizing temperature for the removal of commercial sizing, adjusting the drying temperature, as well as optimizing the corresponding residence time of carbon fibres passing through the furnaces. The highest production rate, reaching 1 m sized carbon fibres per minute, was achieved by employing a desizing temperature of 550 °C, a drying temperature of 250 °C, and a residence time of 1 min. Furthermore, a range of sizing solutions was investigated and formulated, exploring carbon-based nanomaterial types with different surface functionalizations and concentrations, to evaluate their impact on the surface morphology and mechanical properties of carbon fibres. In-depth analyses, including scanning electron microscopy and contact angle goniometry, revealed the achievement of a uniform coating on the carbon fibre surface, leading to an enhanced affinity between fibres and the polymeric epoxy matrix. The incorporation of nanomaterials, specifically N₂-plasma-functionalized carbon nanotubes and few-layer graphene, demonstrated notable improvements in the interfacial shear properties (90% increase), verified by mechanical and push-out tests. Full article

(This article belongs to the Topic Advanced Composites Manufacturing and Plastics Processing)

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20 pages, 15289 KiB

Open AccessArticle

Processing and Analysis of Hybrid Fiber-Reinforced Polyamide Composite Structures Made by Fused Granular Fabrication and Automated Tape Laying

by Patrick Hirsch, Simon Scholz, Benjamin Borowitza, Moritz Vyhnal, Ralf Schlimper, Matthias Zscheyge, Ondrej Kotera, Michaela Stipkova and Sebastian Scholz

J. Manuf. Mater. Process. 2024, 8(1), 25; https://doi.org/10.3390/jmmp8010025 - 01 Feb 2024

Viewed by 1392

Abstract

Fused granular fabrication (FGF) is a large format additive manufacturing (LFAM) technology and focuses on cost-effective granulate-based manufacturing by eliminating the need for semifinished filaments. This allows a faster production time and a broader range of usable materials for tailored composites. In this study, the mechanical and morphological properties of FGF test structures made of polyamid 6 reinforced with 40% of short carbon fibers were investigated. For this purpose, FGF test structures with three different parameter settings were produced. The FGF printed structures show generally significant anisotropic mechanical characteristics, caused by the layer-by-layer building process. To enhance the mechanical properties and reduce the anisotropic behavior of FGF structures, continuous unidirectional fiber-reinforced tapes (UD tapes), employing automated tape laying (ATL), were subsequently applied. Thus, a significant improvement in the flexural stiffness and strength of the manufactured FGF structures was observed by hybridization with 60% glass fiber-reinforced polyamide 6 UD tapes. Since the effectiveness of UD-tape reinforcement depends mainly on the quality of the bond between the UD tape and the FGF structure, the surface quality of the FGF structure, the interface morphology, and the tape-laying process parameters were investigated. Full article

(This article belongs to the Topic Advanced Composites Manufacturing and Plastics Processing)

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Journal Name	Impact Factor	CiteScore	Launched Year	First Decision (median)	APC
Fibers fibers	3.9	7.0	2013	24.1 Days	CHF 2000	Submit
Journal of Composites Science jcs	3.3	4.5	2017	14.7 Days	CHF 1800	Submit
Journal of Manufacturing and Materials Processing jmmp	3.2	5.5	2017	14.2 Days	CHF 1800	Submit
Materials materials	3.4	5.2	2008	13.9 Days	CHF 2600	Submit
Polymers polymers	5.0	6.6	2009	13.7 Days	CHF 2700	Submit

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