Processing of Thermoplastic Composite Structures Gabriel Gumede Department of Mechanical Engineering Durban University of Technology November 2007.

Processing of Thermoplastic Composite Structures

Gabriel Gumede

Department of Mechanical EngineeringDurban University of Technology

November 2007

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Introduction

• What is Thermoplastic compositeThermoplastic :Deformable, melts to liquid and freezes to brittle glass

state.Recyclable (remelted and remoulded).

Composite :Material made from two or more materials with different physical or chemical properties and remain separate

and distinct within the finished structure.

Thermoplastic composite is a recyclable, reinforced plastic material.

• Polymeric composite application

Automotive, aerospace, marine, civil construction, sports, and many others.

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Problem Statement

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• Nanocomposites

• Vacuum Bagging

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• Autoclaving

Enhances composite bonding and curing.

• Resin Transfer Moulding

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• Thermoforming

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Work already done

• Kunihiko Murayama - orietation control of short fibres in a - liquid matrix by loading a magnetic field. - Nickel coated graphite fibre - ultrasonic vibration

• Liu and Chen developed water-assisted injection moulding technology. Water penetrates into the core of the composite and pushes the material into the mould wall thereby aligning the fibres in the mould direction.

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Manufacturing Processes

• Pultrusion

• Extrusion moulding

• Compression moulding

• Injection moulding

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Pultrusion Process

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Modified Pultrusion/Extrusion Moulding Process

creel

Fibre spreader

Heater rollers

Impregnating toolWith rollers

chiller

Pullers

Winder

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Impregnating Tool Rollers

Tool mouth

Fibre entrance port

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Extrusion moulding

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Principle of a Plasticator

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Compression moulding

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Injection moulding

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Thermoplastic Pellets (TP)

Glass fibres

Process Chart

Modified Pultrusion TP with glass fibres

Heating

Extrusion

Hot pressing

Components

Injection moulding

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Fibre Orientation

• Factors affecting fibre orientation

Moulding processes

Gates, Initial Charge and Part Geometry

Thickness of the moulded part

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Outline of Research

• Develop a technique of aligning glass fibres using extrusion, injection and compression moulding processes.

• Optimise the mechanical properties by controlling the fibre orientation.

• Determine critical fibre length

• Produce complex shaped reinforced thermoplastic composite components.

• Test and analyse reinforced thermoplastic components.

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I would like to thank Kenton for

their support through the Hystou programme