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

Shailesh Alwekar; Ryan Ogle; Seokpum Kim; Uday Vaidya

doi:10.1016/j.compositesb.2020.108597

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

Shailesh Alwekar, Ryan Ogle, Seokpum Kim, Uday Vaidya

Composites Innovation

Research output: Contribution to journal › Article › peer-review

29 Scopus citations

Abstract

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. 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.

Original language	English
Article number	108597
Journal	Composites Part B: Engineering
Volume	207
DOIs	https://doi.org/10.1016/j.compositesb.2020.108597
State	Published - Feb 15 2021

Funding

This research was supported by the Institute for Advanced Composites Manufacturing Innovation (IACMI) , DOE Office of Energy Efficiency and Renewable Energy , Advanced Manufacturing Office and used resources at the Manufacturing Demonstration Facility, a DOE-EERE User Facility at Oak Ridge National Laboratory. The authors would like to acknowledge the postdoctoral research associate Stephen A. Young and Dr. Nitilaksha Hiremath for their efforts towards the research. This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy . The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan ( http://energy.gov/downloads/doe-public-access-plan ). This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan).This research was supported by the Institute for Advanced Composites Manufacturing Innovation (IACMI), DOE Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office and used resources at the Manufacturing Demonstration Facility, a DOE-EERE User Facility at Oak Ridge National Laboratory. The authors would like to acknowledge the postdoctoral research associate Stephen A. Young and Dr. Nitilaksha Hiremath for their efforts towards the research.

Keywords

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

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10.1016/j.compositesb.2020.108597

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title = "Manufacturing and characterization of continuous fiber-reinforced thermoplastic tape overmolded long fiber thermoplastic",

abstract = "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, G1c for tape overmolded LFT was higher by 25–30% compared to literature reported G1c. 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. 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.",

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AB - 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, G1c for tape overmolded LFT was higher by 25–30% compared to literature reported G1c. 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. 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.

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

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