Manufacturing of Hybrid Yarn Thermoplastic Composites by the Method of Filament Winding

Abstract

Filament winding is a manufacturing method to produce composite materials with a thermosetting or thermoplastic matrix impregnated continuous fibers. Due to the high melt viscosity of thermoplastics, some problems such as inadequate fiber dispersion in the structure, low wetting ability, and interface quality problems between matrix and fiber might emerge. Preforms can be used in order to solve these problems in the continuous fiber reinforced composite manufacturing; division of the polymer can be made using either powder or fiber form. In this study, polyethylene/E-glass fiber and polypropylene/E-glass fiber hybrid yarns were used as materials to produce thermoplastic composite structures. Firstly, plate samples were produced at various temperatures, periods of time and different thicknesses of ply. After the preparation of samples tensile test, 3 point bending flexural test, and calcination test were applied and Scanning Electron Microscopy (SEM) observations were also performed to these samples, and then the production parameters were optimized. After that, cylindrical shaped samples were produced by a laboratory-type manual filament winding device and ring stiffness tests were performed. According to the test results of the plate samples, the optimum production conditions were determined as 200 °C for 5 minutes for polyethylene/E-glass fiber composite structure and 220 °C for 5 minutes for polypropylene/E-glass fiber composite structure. Mechanical test results of plate samples revealed that polypropylene composites presented slightly better results than polyethylene ones. Additionally, in the cylindrical specimens, close results to the ring stiffness values determined by the standards were obtained.

Keywords

• Thermoplastic composites,Hybrid yarns,Filament winding

References

1. Zu, L., “Design and Optimization of Filament Wound Composite Pressure Vessels”, Phd. Thesis, Delft University of Technology, Delft, (2012).
2. Green, J. E., Composite Filament Winding, Peters S.T., ASM International, Ohio, (2011).
3. Friedrich, K., Polypropylene an A-Z reference, 1st. ed., Vol. 2, Karger-Kocsis, J., Kluwer Academic Publishers, 81-87, UK, (1999).
4. Karpuz, P., “Mechanical Characterization of Filament Wound Composite Tubes by Internal Pressure Tests”, MSc. Thesis, Middle East Technical University, Ankara, (2005).
5. Dave, R.S., Loos, A.C., Processing of Composites, Carl Hanser Verlag, Munich, 1999.
6. Schwartz, M. M., Composite Materials, Volume II: Processing, Fabrication, and Applications, Springer-Verlag, Berlin, 15-17, (2017).
7. Mallick, P. K., Fiber Reinforced Composites Materials, Manufacturing and Design, 3rd ed., CRC Press, Dearborn, Michigan, 408-416, (2007).
8. Schuster, J., Duhovic, M., Bhattacharyya, D., Manufacturing and Processing of Polymer Composites, Bhattacharyya, D., Fakirov, S., Carl Hanser Verlag, Munich, 10-15, (2012).

9. Grouve, W. J. B., Akkerman, R., A Consolidation Process Model for Film-Stacking Glass/PPS Laminates, 17th International Conference on Composite Materials, Edinburgh, (2009).
10. Svensson, N., Shishoo, R., Gilchrist, M., “Manufacturing of Thermoplastic Composites from Commingled Yarns-A Review”, Journal of Thermoplastic Composite Materials, 11: 22-56, (1998).
11. Risicato J.-V., Kelly F., Soulat D., Legrand X., Trümper W., Cochrane C., Koncar V., “A Complex shaped reinforced thermoplastic composite part made of commingled yarns with integrated sensor”, Applied Composite Materials, 22 (1): 81-98, (2015).
12. Alagirusamy, R., Das A., Technical Textile Yarns Industrial and Medical Applications, 1st ed., Vol. 101, Woodhead Publishing, Cambridge, (2010).
13. Bernet, N., Michaud, V., Bourban, P-E., Manson, J-A. E., “Commingled yarn for rapid processing of complex shapes”, Composites Part A: Applied Science and Manufacturing, 32: 1613-1626 (2001).
14. Mankodi, H. R., Specialist Yarn and Fabric Structures Developments and Applications, Gong, R. H., Woodhead Publishing, vol. 123, 21, Cornwall, UK (2011).
15. Lauke, B., Bunzel, U., Schneider, K., “Effect of hybrid yarn structure on the delamination behaviour of thermoplastic composites”, Composites Part A: Applied Science and Manufacturing, (29): 1397-1409, (1998).
16. Choi, B.-D., Diestel, O., Offermann, P., “Commingled CF/PEEK hybrid yarns for use on textile reinforced high performance rotors”, ICCM International Committee on Composite Materials, Paris, (2000).
17. ISO 527-5, (2009), “Plastics-Determination of tensile properties-Part 5: Test conditions for unidirectional fibre-reinforced plastic composites”, London, UK: ISO.
18. BS EN ISO 14125, (1998+A1:2011), “Fibre-reinforced plastic composites. Determination of flexural properties”, London, UK: BSI-ISO.
19. BS EN 1852-1, (2009), "Plastics piping systems for non-pressure underground drainage and sewerage. Polypropylene (PP)", London, UK: BSI.
20. BS EN 12666-1, (2005+A1:2011), “Plastics piping systems for non-pressure underground drainage and sewerage Polyethylene (PE)”, London, UK: BSI.
21. BS EN ISO 1172 (1996), “Textile-glass-reinforced plastics-Prepregs, moulding compounds and laminates-Determination of the textile-glass and mineral-filler content-Calcination methods”, London, UK: BSI-ISO.
22. Ebewele, R. O., “Polymer Science and Technology”, CRC Press LLC, 419-469, Florida, (2000).
23. Carraher, C. E., Jr., “Polymer Chemistry”, 6th Ed., Marcel Dekker, Inc., Florida, (2003).
24. BS EN ISO 9969 (2016), “Thermoplastics pipes. Determination of ring stiffness”, London, UK: BSI.