The SPE Library contains thousands of papers, presentations, journal briefs and recorded webinars from the best minds in the Plastics Industry. Spanning almost two decades, this collection of published research and development work in polymer science and plastics technology is a wealth of knowledge and information for anyone involved in plastics.
Yi Zhao, Christopher Hess, Eric v.k. Hill, Cheng-Shung Wang, May 2004
Barely visible impact damage in composite structures is difficult to detect. The predominant failure mechanism is delamination, which is easily detected by C-scan. Using pixel data from C-scan image, coupled with acoustic emission amplitude distribution data from compression after impact testing, and applying it to a back propagation neural network, correlations on ultimate strength can be made with great accuracy. This paper demonstrates the ability to predict the ultimate compressive strengths of composite structures using this approach.
S. Yuen, C. Fan, T. Kuboki, P.-Y.B. Jar, T.W. Forest, J.J.R. Cheng, May 2004
Using a recently developed Beam Test method, a study has been conducted to identify experimental conditions that are required to initiate delamination propagation in fibre-reinforced polymers when subjected to transverse loading. This paper reports experimental results of the loading levels that are required for the onset of delamination in different interlaminar regions. The results suggest that the loading level required for delamination varies with size of the loading pin and location of the interlaminar region, but the energy-based delamination resistance, that is, energy absorption per unit area of delamination growth, remains nearly constant. Information obtained from the study will be implemented in finite element models (FEM) to identify local fracture criteria for the on-set of delamination in FRP under transverse loading.
Elisabeth Ladstätter, Gerald Pinter, Wolfgang Billinger, Reinhold W. Lang, May 2004
In this work a new evaluation method for characterization of the fatigue behavior of carbon/epoxy laminates, manufactured in the Resin Transfer Molding (RTM) process, is introduced. Fatigue data are represented in so called isocyclic stress-strain diagrams (ISSD) by plotting pairs of stress and associated strain values for each 10xth cycle. Isocyclic stress-strain curves are comparable to isochronous stress-strain-curves for static tests. This paper concentrates on the characterization of laminates with compacted fabric packages applying binder and sewing techniques infused with a RTM epoxy resin.
C.R. Rios, S.L. Ogin, C. Lekakou, K.H. Leong, May 2004
In this work the tensile properties and failure mechanisms for a knitted fabric reinforced composite has been investigated. Two commercial composites manufactured with Milano 2x68 tex knitted fabric as a reinforcement and Derakane vinyl ester resin as matrix were analysed. The quasi-static behaviour of the materials has been analysed as a function of tested direction, including an investigation of the damage accumulation. Characterization of these materials under tensile loading has been carried out for monotonic and cyclic loading and the results have been compared with those found earlier for a single layer and the sandwich model material with epoxy resin as matrix1. Various failure mechanisms such as cracking at loop cross-over points, resin matrix cracking, fibre bundle debonding and tensile fracture of fibre bundles in failed specimens were observed.
Masahide Kawamura, Asami Nakai, Hiroyuki Hamada, May 2004
This paper describes warpage prediction method for compression molded SMC products. It was found that anisotropy of the coefficient of thermal expansion caused by fiber orientation distribution and the inversion phenomenon of temperature gradient in the thickness direction during the curing process were dominated in inducing warpage. Warpage prediction method utilizing finite element method has been developed based on these causes of warpage. Predicted warpage coincides well with warpage of molded products quantitatively. This warpage prediction method is able to reduce warpage of compression molded SMC products.
Uday K. Vaidya, Francis Samalot, Klaus Gleich, May 2004
Fiber reinforced polypropylene (PP) and nylon have application potential in front-end parts, bumper beams, floor panels and under body shields of mass transit vehicles. Currently mass transit buses feature a metallic skeletal frame with plywood flooring. The present study focuses on the design through prototype manufacture of a representative thermoplastic composite floor component for a mass transit bus. A vacuum thermoformed hat-sine shaped rib stiffened floor panel was developed. Weight savings up to 40% are realized using thermoplastic composites as compared to the conventional metal-plywood design.
A new method is developed to produce cost-effective bipolar plates with high electrical conductivity, high corrosion resistance, excellent mechanical properties, and rapid manufacturability. Composite sheets consisting of graphite particles, polyester and glass fibers are first generated by means of a wet-lay process. The porous sheets are then stacked and covered with fluoropolymer/graphite particles and compression molded to form layered composite bipolar plates with gas flow channels and other features. The low-cost polyester and glass in the core contribute strength and stiffness while the fluoropolymer in the skin layer provides a barrier to H2, O2, water and corrosive chemicals. The test shows that the plates containing 67 wt-% graphite have bulk conductivity and mechanical properties (flexural strength) higher than fluoropolymer/graphite composite plates containing 74% of graphite.
Polymer-matrix composites with continuous carbon fiber reinforcement are widely used for lightweight structures such as airframes. Non-structural functions such as strain/stress sensing, temperature sensing, and damage monitoring have been attained in these structural composites by exploiting the resistive, piezoresistive and thermoelectric behavior. These functions are important for smart structures, vibration control and hazard mitigation. The multifunctionality of the structural material reduces the need for embedded devices, thus saving cost, enhancing durability, increasing the functional volume and avoiding mechanical property loss.
Plastic Composites derive their excellent and varied properties from the combination of different resins and fillers; thus gaining true synergy. Multi-temperature Composite Metal Tooling1 is designed to do the same for a mold cavity. This is accomplished by using hard, tough materials for strength and molding surface; then replacing the steel behind the molding surface with material with high thermal conductivity. This results in the same type of 2+2=5 synergy achieved in composite plastics. Composite Metal Tooling (CMT) can then be combined with a variable mold temperature control to truly optimize both the filling of the cavity and cycle time.
It is now well recognized that continuous fiber reinforced thermoplastic (CFRTP) composites offer significant advantages over thermoset composites and metals for structural parts. However, processing of this material presents some limitation. Matched-die moulding and diaphragm forming are generally used and other techniques such as rubber forming, hydroforming and rubber pressing techniques derived from the sheet metal industry, have been adapted to the forming of these materials. Unfortunately, all these processes have important limits with regards to their ability to conform and consolidate rapidly and efficiently the complex shaped over the mould surface. To address this problem, new tooling concept was developed. This technology allows production of good quality parts at high volume production while keeping low the development and fabrication costs.
Kamal K. Kar, Shiv D. Sharma, Prashant Kumar, Joshua U. Otaigbe, May 2004
A rubber pressure molding technique is developed to prepare a fiber reinforced plastic (FRP) product. The technique is based on the matching die set, where the die is made of hard metal like steel and the punch from the flexible rubber like material, natural rubber. The use of flexible rubber punch applies hydrostatic pressure on the surface of the product. A split steel die and rubber punch are designed and fabricated to prepare the FRP product. The same split die is also used to cast the rubber punch. Polyester resin does not cure in presence of natural rubber, but epoxy resin cures well. Burn test, coin test and microstructure studies are conducted on the products to find out the void content, presence of delamination and bonding between fiber and resin. The characterization of product is carried out by the mechanical testing like interlaminar fracture toughness, interlaminar shear test and tension test.
Wern-Shiarng Jou, Huy-Zu Cheng, Chih-Feng Hsu, Cheng-Ju. Chang, May 2004
Both the electromagnetic (EM) shielding effectiveness (SE) of multi-wall carbon nanotubes (MWNTs) and hollow carbon nanocapsules (HCNCs) composites have been investigated. The MWNTs from two different makers and the HCNCs from one maker were fabricated with plastics to make the composites. The SE of both MWNTs and HCNCs composites achieve 40 dB, which is a requirement for industrial application as the weight percentage of the MWNTs and the HCNCs reach 4% and 8%, respectively. The weight percentage of these nano materials added into the plastics is much lower than that required for the typical carbon fibers/plastics composites (30%) for the same SE performance in comparison.
Partially aligned and oriented Polyacrylonitrile (PAN) nanofibers were prepared from solution with dimethylformamide by electrospinning with the purpose of preparing carbon nanofibers for the reinforcement of thin films. Aligned (+) birefringent fibers with diameters between 0.27-0.29?m (FESEM) were prepared from a 15wt% solution, electrospun at 16kV, and collected onto a wheel rotating with a surface velocity of 3.5-12.3m/s. The molecular orientation within the fibers was examined by X-ray diffraction (WAXD) and dichroism (FTIR). A maximum chain orientation parameter, f, of 0.23 was determined for collection speeds between 8.1-9.8m/s. Twisted yarns of aligned PAN nanofibers with twist angles between 1.1° and 16.8° were prepared. The ultimate strength and modulus of the twisted yarns increased with increasing angle of twist to a maximum of 162 ±8.5 MPa and 5.9 ±0.3 GPa, respectively, at an angle of 9.3°.
Unsaturated polyester (UP) resins are one of the most widely used materials in fabricated composites. However, a number of problems caused by their high polymerization shrinkage have limited their growth in many new markets. Our research results showed that 1-3 wt% of nanoclay can provide excellent volume shrinkage control of UP resin systems containing polyvinyl acetate (PVAc) as a low profile additive (LPA) in room temperature molding processes. Nanoclay residing in the LPA-rich phase led to a higher reaction rate and earlier onset of micro-cracking in the resin system. Consequently, an earlier volume expansion during curing was observed in the reactive dilatometry experiment, resulting in better shrinkage control.
The effect of deformation temperature on fundamental deformation-structure relationships in amorphous compression molded and melt cast Poly(lactic acid) (PLA) films with varying nanoclay loadings were investigated using a stretch birefringence apparatus that allows for direct measurement of true stress, true strain, and birefringence. Behavior of the crystalline phase was elucidated with WAXD. Relationships between stress, strain, and birefringence are strongly affected by stretching temperature, clay loading, and film production methodology. The effect of these variables on the molecular mechanisms of uniaxial deformation in rubbery state PLA films and its affect on the various levels of structure are elucidated in this study.Our studies indicate that the introduction of a relatively small fraction nanoparticles leads to strain hardening at lower values of true strain when the films are stretched from rubbery state. This allows the self-leveling mechanism that helps obtain uniform film thicknesses, to be tailored to specific need of the process and application.
U.S. Ishiaku, Y.W. Leong, O.A. Khondker, A. Nakai, H. Hamada, May 2004
This presentation focuses on effects of injection speed and weld line on the properties of PBS/Jute fiber composites. It was found that toughness especially elongation at break is sensitive to the presence of weld line while tensile modulus and flexural properties are little affected. The presence of jute fibers improved toughness i.e. retention of EB and impact strength across the weld line. Ultrahigh speed injection facilitated the recovery of EB and hence toughness. Morphological studies with SEM revealed that some of the jute fibers were aligned across the weld line.
M.A. Dweib, T.A. Bullions, A.C. Loos, R.P. Wool, May 2004
Nonwoven mats of cellulose and keratin fiber were manufactured from recycled kraft paper, newspaper, and processed chicken feathers using a wetlay process. Hybrid fiber mats were produced by mixing different ratios of the three fiber types together in the wetlay process. Composite materials were manufactured by infiltrating these mats with an acrylated epoxidized soybean oil- (AESO) based resin using vacuum assisted resin transfer molding (VARTM). The room temperature cured composite panels contained between 16 and 25% by weight fiber depending on the original mat structure. The fiber mats contained 0 to 50 wt% recycled milled newspaper, 40 to 100 wt% pulp fiber recycled from kraft paper and 0 to 60 wt% cleaned and chopped feathers. These composites are low cost, environmentally friendly, derived from renewable resources, energy efficient, and could be used in many applications such as civil infrastructure, automotive and trucking, temporary roadway matting.
Wanjun Liu, A.K. Mohanty, M. Misra, L.T. Drzal, May 2004
Chemical modification of soy plastic with monomers such as maleic anhydride, glycidyl methacrylate and styrene was accomplished by using reactive extrusion technology. Thermal and mechanical properties of modified soy protein plastic were characterized by using Differential Scanning Calorimetry, Dynamic Mechanical Analyzer and United Testing System. It was found that the denaturation temperature, the glass transition temperature and ( relaxation temperature of soy flour plastic changed and hence tensile properties of modified soy protein plastic improved.
Igor ?ati?, Zvonko Glavina, Maja Rujni?-Sokele, May 2004
There are different reasons why the production of polyester composites with natural reinforcements, like jute can be of interest. One of them is to fabricate the hybrid composites with cheap waste jute sacks as reinforcements in combination with glass mat. The laminates have been fabricated with a different number of jute and glass mat layers and different type of polyester resins. Also, the content of cross-linking agent has been varied. As the indicator of change of mechanical properties, tensile and flexural strength as well as tensile and flexural modulus have been determined. Based on the planned experiments and statistical analysis it can be concluded that in comparison with glass mat polyester composites, the mechanical properties of hybrid composites in optimal combination of glass and jute reinforcements are lower, but at the same time the laminates are 15 to 20% cheaper.
Polypropylene nanocomposites with layered silicates have been prepared with and without edge functionalization by melt processing. The resulting composites were subjected to uniaxial extensional flow in the core of axisymmetric converging dies at strain rates of up to 5 s-1 and a Hencky strain of about 5. The edge treated clay led to a much greater level of exfoliation as determined by XRD, TEM and dynamic viscosity measurements. We observe that at the high strains, the nanolayers are predominantly oriented parallel to the flow direction in the core, in contrast to the perpendicular orientation reported by Okamoto et al. for uniaxial extension of nanocomposite strips to a strain of 1.3.
Kim McLoughlin Senior Research Engineer, Global Materials Science Braskem
A Resin Supplier’s Perspective on Partnerships for the Circular Economy
About the Speaker
Kim drives technology programs at Braskem to develop advanced polyolefins with improved recyclability and sustainability. As Principal Investigator on a REMADE-funded collaboration, Kim leads a diverse industry-academic team that is developing a process to recycle elastomers as secondary feedstock. Kim has a PhD in Chemical Engineering from Cornell. She is an inventor on more than 25 patents and applications for novel polyolefin technologies. Kim is on the Board of Directors of SPE’s Thermoplastic Materials & Foams Division, where she has served as Education Chair and Councilor.
A Resin Supplier’s Perspective on Partnerships for the Circular Economy
About the Speaker
Gamini has a BS and PhD from Purdue University in Materials Engineering and Sustainability. He joined Penn State as a Post Doctorate Scholar in 2020 prior to his professorship appointment. He works closely with PA plastics manufacturers to implement sustainability programs in their plants.
A Resin Supplier’s Perspective on Partnerships for the Circular Economy
About the Speaker
Tom Giovannetti holds a Degree in Mechanical Engineering from The University of Tulsa and for the last 26 years has worked for Chevron Phillips Chemical Company. Tom started his plastics career by designing various injection molded products for the chemical industry including explosion proof plugs and receptacles, panel boards and detonation arrestors for 24 inch pipelines. Tom also holds a patent for design of a polyphenylene sulfide sleeve in a nylon coolant cross-over of an air intake manifold and is a Certified Plastic Technologist through the Society of Plastic Engineers. Tom serves on the Oklahoma Section Board as Councilor, is also the past president of the local Oklahoma SPE Section, and as well serves on the SPE Injection Molding Division board.
Joseph Lawrence, Ph.D. Senior Director and Research Professor University of Toledo
A Resin Supplier’s Perspective on Partnerships for the Circular Economy
About the Speaker
Dr. Joseph Lawrence is a Research Professor and Senior Director of the Polymer Institute and the Center for Materials and Sensor Characterization at the University of Toledo. He is a Chemical Engineer by training and after working in the process industry, he has been engaged in polymers and composites research for 18+ years. In the Polymer Institute he leads research on renewably sourced polymers, plastics recycling, and additive manufacturing. He is also the lead investigator of the Polyesters and Barrier Materials Research Consortium funded by industry. Dr. Lawrence has advised 20 graduate students, mentored 8 staff scientists and several undergraduate students. He is a peer reviewer in several journals, has authored 30+ peer-reviewed publications and serves on the board of the Injection Molding Division of SPE.
Matt Hammernik Northeast Account Manager Hasco America
A Resin Supplier’s Perspective on Partnerships for the Circular Economy
About the Speaker
Matt Hammernik serves as Hasco America’s Northeast Area Account Manager covering the states Michigan, Ohio, Indiana, and Kentucky. He started with Hasco America at the beginning of March 2022. Matt started in the Injection Mold Industry roughly 10 years ago as an estimator quoting injection mold base steel, components and machining. He advanced into outside sales and has been serving molders, mold builders and mold makers for about 7 years.
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