Manufacturing and characterization of continuous fiber-reinforced thermoplastic tape overmolded long fiber thermoplastic

Alwekar, Shailesh; Ogle, Ryan C.; Kim, Pum; Vaidya, Uday

doi:10.1016/j.compositesb.2020.108597

Title: Manufacturing and characterization of continuous fiber-reinforced thermoplastic tape overmolded long fiber thermoplastic

Journal Article · Wed Dec 23 00:00:00 EST 2020 · Composites Part B: Engineering

DOI:https://doi.org/10.1016/j.compositesb.2020.108597· OSTI ID:1819534

Alwekar, Shailesh ^[1];

^[1];

^[2]; Vaidya, Uday ^[3]

Univ. of Tennessee, Knoxville, TN (United States); Inst. for Advanced Composites Manufacturing Innovation (IACMI), Knoxville, TN (United States)
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Univ. of Tennessee, Knoxville, TN (United States); Inst. for Advanced Composites Manufacturing Innovation (IACMI), Knoxville, TN (United States); Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

Light-weight construction, design freedom, integration of functions, and compelling cost element are desired by Original Equipment Manufacturers (OEMs) and their suppliers. The emergence of overmolding of continuous-discontinuous reinforcement enables design freedom and ability to tailor stiffness, strength, and damage tolerance for structural applications. In this work, long fiber thermoplastics (LFT) are overmolded with continuous fiber-reinforced thermoplastic (CFRTP) tape are combined using extrusion compression molding process to evaluate the structural performance. The CFRTP tape overmolded LFT samples were characterized using nondestructive and destructive techniques to track fiber alignment, fiber distribution, manufacturing defects, interfacial bonding of the tape – LFT and effect of CFRTP tape on LFT. Mode 1 fracture toughness, G_1c for tape overmolded LFT was higher by 25–30% compared to literature reported G_1c. This response was attributed to excellent fiber distribution, good fiber wetting, and absence of voids at the interface. Three-point bend test indicated that CFRTP tape overmolded LFT composites were better able to resist damage under the bending load compared to constituent LFT composite. Flexural strength of the overmolded composite was higher by 119–142%, and modulus higher by 77–65% compared to constituent LFT composite. Simulated flexural results accurately represents the mechanical behavior of composites. Here, the penetration energy of tape overmolded LFT composites determined by LVI test was in the range of 27.66–30.15 J, which is significantly higher than constituent LFT composite, 7.76 J. CFRTP tape overmolded LFT composite exhibits progressive fiber fracture, matrix cracking, and interfacial debonding failure, whereas, constituent LFT composite showed catastrophic fiber fracture.

View Accepted Manuscript (DOE)

View Accepted Manuscript (Publisher)

Cite

Export

Save

Research Organization:: Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 1819534

Alternate ID(s):: OSTI ID: 1809754

Journal Information:: Composites Part B: Engineering, Vol. 207; ISSN 1359-8368

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

References (16)

Polypropylene/glass fibre 3D-textile reinforced composites for automotive applications Hufenbach, W.; Böhm, R.; Thieme, M. Materials & Design, Vol. 32, Issue 3 https://doi.org/10.1016/j.matdes.2010.08.049	journal	March 2011
Application of iterative reconstruction algorithms to mitigate CT-artefacts when measuring fiber reinforced polymer materials Wilbers, Arnold; Biguri, Ander; Schillings, Jennifer Polymer, Vol. 177 https://doi.org/10.1016/j.polymer.2019.06.004	journal	August 2019
A phenomenological study of the mechanical properties of long-fiber filled injection-molded thermoplastic composites Stokes, V. K.; Inzinna, L. P.; Liang, E. W. Polymer Composites, Vol. 21, Issue 5 https://doi.org/10.1002/pc.10223	journal	October 2000
LFT – development status and perspectives Schemme, Michael Reinforced Plastics, Vol. 52, Issue 1 https://doi.org/10.1016/S0034-3617(08)70036-5	journal	January 2008
Correction to the Fukuda-Kawata Young's modulus theory and the Fukuda-Chou strength theory for short fibre-reinforced composite materials Jayaraman, K.; Kortschot, M. T. Journal of Materials Science, Vol. 31, Issue 8 https://doi.org/10.1007/BF00356627	journal	April 1996
Physical state of the amorphous phase of polypropylene-influence on thermo-mechanical properties Krajenta, Artur; Rozanski, Artur Polymer, Vol. 70 https://doi.org/10.1016/j.polymer.2015.06.020	journal	July 2015
Crystallization Behavior and Properties of Glass Fiber Reinforced Polypropylene Composites Wang, Yuming; Cheng, Lihong; Cui, Xiaoqian Polymers, Vol. 11, Issue 7 https://doi.org/10.3390/polym11071198	journal	July 2019
Polyamide 6?long glass fiber injection moldings Bijsterbosch, H.; Gaymans, R. J. Polymer Composites, Vol. 16, Issue 5 https://doi.org/10.1002/pc.750160504	journal	October 1995
Review of low-velocity impact properties of composite materials Richardson, M. O. W.; Wisheart, M. J. Composites Part A: Applied Science and Manufacturing, Vol. 27, Issue 12 https://doi.org/10.1016/1359-835X(96)00074-7	journal	January 1996
SMC has plenty of road to run in automotive applications McConnell, Vicki P. Reinforced Plastics, Vol. 51, Issue 1 https://doi.org/10.1016/S0034-3617(07)70027-9	journal	January 2007
A State-of-the-Art Review on Debonding Failures of FRP Laminates Externally Adhered to Concrete Kang, Thomas H. -K.; Howell, Joe; Kim, Sanghee International Journal of Concrete Structures and Materials, Vol. 6, Issue 2 https://doi.org/10.1007/s40069-012-0012-1	journal	June 2012
X-ray computed tomography of polymer composites Garcea, S. C.; Wang, Y.; Withers, P. J. Composites Science and Technology, Vol. 156 https://doi.org/10.1016/j.compscitech.2017.10.023	journal	March 2018
Design and Manufacturing Issues in the Development of Lightweight Solution for a Vehicle Frontal Bumper Beyene, A. T.; Koricho, E. G.; Belingardi, G. Procedia Engineering, Vol. 88 https://doi.org/10.1016/j.proeng.2014.11.129	journal	January 2014
Mode I interlaminar crack propagation in continuous glass fiber/polypropylene composites: temperature and molding condition dependence Perrin, F.; Bureau, M. N.; Denault, J. Composites Science and Technology, Vol. 63, Issue 5 https://doi.org/10.1016/S0266-3538(02)00255-5	journal	April 2003
Finite element analysis of a low-velocity impact test for glass fiber-reinforced polypropylene composites considering mixed-mode interlaminar fracture toughness Jung, Ku-Hyun; Kim, Do-Hyoung; Kim, Hee-June Composite Structures, Vol. 160 https://doi.org/10.1016/j.compstruct.2016.10.093	journal	January 2017
Process simulation, design and manufacturing of a long fiber thermoplastic composite for mass transit application Balaji Thattaiparthasarathy, K.; Pillay, S.; Ning, H. Composites Part A: Applied Science and Manufacturing, Vol. 39, Issue 9 https://doi.org/10.1016/j.compositesa.2008.05.017	journal	September 2008

Similar Records

Internal arcing and lightning strike damage in short carbon fiber reinforced thermoplastic composites

Journal Article · Sun Nov 01 00:00:00 EDT 2020 · Composites Science and Technology · OSTI ID:1819534

Kumar, Vipin; Yeole, Pritesh; Hiremath, Nitilaksha; +8 more

Melt extruded versus extrusion compression molded glass-polypropylene long fiber thermoplastic composites

Journal Article · Thu Feb 25 00:00:00 EST 2021 · Composites. Part A, Applied Science and Manufacturing · OSTI ID:1819534

Alwekar, Shailesh; Yeole, Pritesh; NLN, Vipin; +3 more

Processing Temperature Effect on Failure Behavior of Unidirectional Thermoplastic Polymer-fiber-reinforced Polymers (PFRPs)

Conference · Tue Nov 14 00:00:00 EST 2023 · OSTI ID:1819534

Qiao, Yao; Ko, Seunghyun; Ramos, Jose L.; +4 more

Related Subjects

42 ENGINEERING
Discontinuous reinforcement
Tape
Computational modeling
Non-destructive testing
Extrusion compression molding

Title: Manufacturing and characterization of continuous fiber-reinforced thermoplastic tape overmolded long fiber thermoplastic

Citation Formats

References (16)

Similar Records

Related Subjects