Reactive extrusion of frontally polymerizing continuous carbon fiber reinforced polymer composites

Hmeidat, Nadim S.; Zakoworotny, Michael; Kim, Yun Seong; Le, Thien B.; DeBrun, Gavin; Shah, Rohan; Lessard, Jacob J.; Moore, Jeffery S.; Baur, Jeffery W.; Geubelle, Philippe H.; Sottos, Nancy R.; Tawfick, Sameh H.

doi:10.1016/j.compositesa.2024.108609

Reactive extrusion of frontally polymerizing continuous carbon fiber reinforced polymer composites

Journal Article · Thu Nov 28 00:00:00 EST 2024 · Composites. Part A, Applied Science and Manufacturing

DOI:https://doi.org/10.1016/j.compositesa.2024.108609· OSTI ID:2479014

^[1]; Zakoworotny, Michael ^[2]; ^[2]; Le, Thien B. ^[2]; ^[2]; ^[2]; Lessard, Jacob J. ^[3]; Moore, Jeffery S. ^[2]; Baur, Jeffery W. ^[2]; ^[2]; ^[2]; ^[2]

University of Illinois at Urbana-Champaign, IL (United States); Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
University of Illinois at Urbana-Champaign, IL (United States)
University of Illinois at Urbana-Champaign, IL (United States); University of Utah, Salt Lake City, UT (United States)

The manufacturing of carbon fiber-reinforced polymer (CFRP) composites demands rapid and energy-efficient strategies. Frontal polymerization (FP) enables the manufacturing of CFRP using dicyclopentadiene (DCPD) thermoset polymer which meets these requirements. In this work, we introduce reactive extrusion of CFRP (RE-CFRP), where two rollers provide localized heat and pressure to sustain the curing reaction and the consolidation of a continuous carbon fiber tow pre-impregnated with DCPD. We study the effect of the extrusion speed, temperature, and compaction force on the properties of the produced CFRP. Mechanical testing confirms that the resulting fiber volume fraction and the elastic modulus are similar to bulk cured tows. A homogenized thermo-chemical model is developed to study the effect of the process parameters on the polymerization reaction. The process produces hollow woven composite tubes directly via extrusion and in situ curing. Overall, this process offers advantages in curing, tooling, speed, and energy.

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

Sponsoring Organization:: DARPA; USDOE Office of Energy Efficiency and Renewable Energy (EERE); USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Materials & Manufacturing Technologies Office (AMMTO)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 2479014

Alternate ID(s):: OSTI ID: 2480033

Journal Information:: Composites. Part A, Applied Science and Manufacturing, Journal Name: Composites. Part A, Applied Science and Manufacturing Vol. 190; ISSN 1359-835X

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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