Impregnation Ability and Micromechanical Assessments of Pultruded GL/PP and GL/PA6 Thermoplastic Prepregs

Mehri-Khansari, Nabi; Ghorbani, Hadi; Golzar, Mohammad

doi:10.22034/jast.2024.452035.1182

Impregnation Ability and Micromechanical Assessments of Pultruded GL/PP and GL/PA6 Thermoplastic Prepregs

Document Type : Original Article

Authors

Nabi Mehri-Khansari ¹

hadi Ghorbani ²

Mohammad Golzar ³

¹ Faculty of Mechanical Engineering, Sahand University of Technology, Tabriz, Iran

² department of Mechanical Engineering, Tarbiat Modares university

³ Tarbiat modares university

10.22034/jast.2024.452035.1182

Abstract

The degree of impregnation directly impacts the ultimate strength of thermoplastic composite (TPC) prepreg. To understand this relationship, an experimental procedure was developed to investigate key factors such as maximum interlaminar shear strength (ILSS), void content, and fiber volume fractions, which influence the residual strength of TPC prepreg. Additionally, three types of dies (A, B, and B+) were produced and examined for injection methods and direct pultrusion of commingled (COM) and side-by-side (SBS) wires. Factors like the fiber/void fraction ratio (Vf/Vv), ILSS, and ILSS/Vf were used to compare the impregnation capacity of each die and production method. The results revealed that the COM method achieved the maximum degree of impregnation, while the SBS method yielded the minimum. A remarkable correlation between the fiber fraction and void fraction was also observed, highlighting the accuracy of the Vf/Vv ratio in assessing impregnation quality. This research provides valuable insights into the factors affecting the residual strength of TPC prepreg and emphasizes the importance of optimizing impregnation techniques for enhanced composite performance. In this context, the samples with a 1% void volume fraction within a higher fiber volume fraction of 60% would demonstrate superior impregnation capacity compared to another sample with the same void volume fraction of 1% but a lower fiber volume fraction of 30%

Keywords

Prepreg

Thermoplastic resin

Pultrusion

Porosity

Subjects

Aerospace Structures

[1] N. Mehri Khansari and M. Aliha, "Mixed-modes (I/III) fracture of aluminum foam based on micromechanics of damage," vol. 32, no. 4, pp. 519-548, 2023, doi: https://doi.org.10.1177/10567895221143809.

[2] M. Ataei-Aazam, M. Safarabadi, M. Beygzade, and N. M. Khansari, "Numerical & experimental assessment of mixed-modes (I/II) fracture of PMMA/hydroxyapatite nanocomposite," Theoretical and Applied Fracture Mechanics, vol. 123, p. 103737, 2023/02/01/ 2023, doi: https://doi.org/10.1016/j.tafmec.2022.103737.

[3] N. M. Khansari, N. Karimi, and M. H. Sabour, "Optimization of Friction Stir Welding by fuzzy logic," in Fuzzy Systems (IFSC), 2013 13th Iranian Conference on, 2013: IEEE, pp. 1-6, doi: https://doi.org/10.1109/IFSC.2013.6675654.

[4] N. Mehri Khansari, H. Danandeh Hesar, S. J. M. B. D. o. S. Zare Hosseinabadi, and Machines, "Orthotropic failure criteria based on machine learning and micro-mechanical matrix adapting coefficient," pp. 1-24, 2024, doi: https://doi.org/10.1080/15397734.2024.2351982.

[5] M. Golzar, J. Sinke, and M. Abouhamzeh, "Novel thermomechanical characterization for shrinkage evolution of unidirectional semi-crystalline thermoplastic prepregs (PPS/CF) in melt, rubbery and glassy states," Composites Part A: Applied Science and Manufacturing, vol. 156, p. 106879, 2022/05/01/ 2022, doi: https://doi.org/10.1016/j.compositesa.2022.106879.

[6] P. Novo, J. F. Silva, J. Nunes, and A. J. C. P. B. E. Marques, "Pultrusion of fibre reinforced thermoplastic pre-impregnated materials," vol. 89, pp. 328-339, 2016, https://doi.org/10.1016/j.compositesb.2015.12.026.

[7] G. Sala, D. J. C. P. A. A. S. Cutolo, and Manufacturing, "The pultrusion of powder-impregnated thermoplastic composites," vol. 28, no. 7, pp. 637-646, 1997, https://doi.org/10.1016/S1359-835X(97)00002-X.

[8] H. Ghorbani, M. Golzar, and A. H. Behravesh, "Modeling of impregnation in the pultrusion of thermoplastic composites," Journal of Science and Technology of Composites, vol. 3, no. 1, pp. 1-42, 2016, (in Persian).
[9] D.-H. Kim, W. I. Lee, K. J. C. s. Friedrich, and technology, "A model for a thermoplastic pultrusion process using commingled yarns," vol. 61, no. 8, pp. 1065-1077, 2001, https://doi.org/10.1016/S0266-3538(00)00234-7.

[10] C. Santulli, R. G. Gil, A. Long, M. J. S. Clifford, and E. O.C. materials, "Void content measurements in commingled E-glass/polypropylene composites using image analysis from optical micrographs," Science and Engineering of Composite Materials, vol. 2, no. 2, pp. 77-90, 2002.
[11] I. Standard, "1172: 2002,"" Textile-glass-reinforced plastic, prepregs, moulding compounds and laminates-Determination of the textile-glass and mineral-filler content-Calcination methods, vol. 4.
[12] I., "Textile‐glass‐reinforced plastics. Prepregs, moulding compounds and laminates. Determination of the textile‐glass and mineral‐filler content. Calcination methods."
[13] K. I. McRae and C. A. Zala, "Attenuation and porosity estimation using the frequency-independent parameter Q," in Review of Progress in Quantitative Nondestructive Evaluation, 1st ed., D. O. Thompson and D. E. Chimenti, Eds. New York, NY: Springer, 1995. pp. 703-710, https://doi.org/10.1007/978-1-4615-1987-4_87.

[14] J. D. Frost and C. Y. Kuo, "Automated Determination of the Distribution of Local Void Ratio from Digital Images," Geotechnical Testing Journal, vol. 19, no. 2, pp. 107-117, 1996, http://dx.doi.org/10.1520/GTJ10334J.

[15] L. A. Carlsson, D. F. Adams, and R. B. Pipes, Experimental characterization of advanced composite materials. CRC press, 2014.
[16] Z. Zhao, K. Zhang, H. Cheng, Y. Zeng, and B. Liang, "Experimental characterization and numerical modelling of bending behavior of carbon fiber unidirectional thermoset prepregs," Journal of Reinforced Plastics and Composites, vol. 43, no. 5-6, pp. 277-292, 2024/03/01 2023, https://doi.org/10.1177/07316844231161397.

[17] D. Stone and B. Clarke, "Ultrasonic attenuation as a measure of void content in carbon-fibre reinforced plastics," Non-destructive testing, vol. 8, no. 3, pp. 137-145, 1975, https://doi.org/10.1016/0029-1021(75)90023-7.

[18] D. Stone and B. J. N.-d. t. Clarke, "Ultrasonic attenuation as a measure of void content in carbon-fibre reinforced plastics," vol. 8, no. 3, pp. 137-145, 1975.
[19] J.W. Gillespie Jr, L.A. Carlsson, R.B. Pipes, "Finite element analysis of the end notched flexure specimen for measuring mode II fracture toughness," vol. 27, no. 3, pp. 177-197, 1986, https://doi.org/10.1016/0266-3538(86)90031-X.

[20] V ASTM D2734-16, Standard Test Methods for Void Content of Reinforced Plastics, Nov 14, 2023.
[21] A. J. D-10, "Standard test method for density of plastics by the density-gradient technique," ed, 2010.
[22] D.-H. Kim, W. I. Lee, and K. Friedrich, "A model for a thermoplastic pultrusion process using commingled yarns," Composites science and technology, vol. 61, no. 8, pp. 1065-1077, 2001, https://doi.org/10.1016/S0266-3538(00)00234-7.

[23] P. J. Bates, Melt impregnation of glass roving in a thermoplastic pultrusion compounding process. 1993.
[24] P. J. Bates, "Melt impregnation of glass roving in a thermoplastic pultrusion compounding process," 1995.
[25] K. J. Bowles and S. J. J. o. c. m. Frimpong, "Void effects on the interlaminar shear strength of unidirectional graphite-fiber-reinforced composites," vol. 26, no. 10, pp. 1487-1509, 1992, doi: https://doi.org/10.1177/002199839202601006.

[26] N. Svensson, R. Shishoo, and M. J. J. o. T. C. M. Gilchrist, "Manufacturing of thermoplastic composites from commingled yarns-A review," vol. 11, no. 1, pp. 22-56, 1998.
[27] P. Nygård, C.-G. J. C. P. A. A. S. Gustafson, and Manufacturing, "Interface and impregnation relevant tests for continuous glass fibre-polypropylene composites," vol. 34, no. 10, pp. 995-1006, 2003.
[28] A. Moradi, C. Sun, Z. J. J. o. R. P. Guan, and Composites, "Facilitating aqueous powder impregnation for manufacturing thermoplastic composites: A prepreg rig design and process optimisation," p. 07316844241243127, 2024.

[29] B. Lv et al., "Analyses of wrinkling mechanisms during forming of multi-layer woven fabric reinforced thermoplastic prepregs," vol. 184, p. 108240, 2024.
[30] T. Kim, E. Jun, M. Um, and W. Lee, "Effect of pressure on the impregnation of thermoplastic resin into a unidirectional fiber bundle," Advances in Polymer Technology: Journal of the Polymer Processing Institute, vol. 9, no. 4, pp. 275-279, 1989.
[31] C. Steggall-Murphy, P. Simacek, S. G. Advani, S. Yarlagadda, and S. Walsh, "A model for thermoplastic melt impregnation of fiber bundles during consolidation of powder-impregnated continuous fiber composites," Composites Part A: applied science and manufacturing, vol. 41, no. 1, pp. 93-100, 2010.
[32] N. Bernet, V. Michaud, P. Bourban, and J. Manson, "An impregnation model for the consolidation of thermoplastic composites made from commingled yarns," Journal of composite materials, vol. 33, no. 8, pp. 751-772, 1999.
[33] H. Ghorbani, B. Ataee, and M. Golzar, "Investigation of Impregnation in a Pultrusion die for glass/polypropylene composite wire," in 3rd International Conference on Composites: Characterization, Fabrication and Application (CCFA-3), 2012, pp. 18-19.