Mise en œuvre des composites

thermoplastiques
1. Introduction : Comparaison thermoplastiques thermodurcissables

2. Thermoplastiques utilisés

3. Les charges et additifs

4. La nature des fibres et renforts

5. Procédés de production de profilés

6. Procédés de production de corps creux

7. Moulage de pièces en petite et moyenne série

8. Moulage de pièces en grande série

9. Conclusions

F Léonardi
1
1. Introduction : Comparaison thermoplastiques thermodurcissables

2
1. Introduction : Comparaison thermoplastiques thermodurcissables

3
1. Introduction : Comparaison thermoplastiques thermodurcissables

4
1. Introduction : Comparaison thermoplastiques thermodurcissables

Viscosité Faible à très faible Élevé

(0.1 à 10 Pa.s) (100 à 1000 Pa.s)

5
1. Introduction : Comparaison thermoplastiques thermodurcissables

6
1. Introduction : Comparaison thermoplastiques thermodurcissables

7
2. Thermoplastics used

There are two types: mass market composites (GD) and high performance composites (HP):

GDs represent 95% of the composites used. These are generally reinforced plastics or reinforced
plastics, the reinforcement rate approaching 30%. In 90% of cases, the anisotropy does not exist or
is not controlled because the reinforcements are short fibers. Reinforcements and dies are at
similar costs.

HPs, mainly used in aeronautics, are expensive. The reinforcements are rather long fibers. The
reinforcement rate is over 50%, and it is the reinforcements that affect the cost. The mechanical
properties (mechanical resistance and rigidity) are much higher than those of metals, unlike GD.

POLYPROPYLENE (Twintex)
POLYAMIDE 6-6
PET
Direct relationship between the nature
POLYAMIDE 12
of the fiber and the nature of the
matrix (price, performance for the
PPS
application)
PEI
PEEK and PEKK
……
2. Thermoplastics used
2. Thermoplastics used
3. Fillers and additives

FILLING : mineral charges

(carbonate, silicate, kaolin,…,),
slightly strengthening effect

REINFORCING :
Short fibers
(especially glass fibers, sometimes carbon or others),
reinforcement in traction and rigidity but lowers impact resistance

Glass microbeads
(solid or hollow, mainly in glass), compression reinforcement

FIRE RETARDANT
Halogen (30%) but more toxic fumes (HCl, HBr, etc.)

Phosphate (20%)  carbonaceous layer + H2O, (dark color)

Inorganic (50%) ex: 2 Al (OH) 3  Al2O3 +3 H20, endothermic

3. Fillers and additives

"CONDUCTOR" : Carbon black, metallic powder, Cu fabric,

Ag paint, Zn spray, metallization
(antistatic or electromagnetic shielding)
Carbon nanotubes (linked to falling prices / industrial production)

DYE - PIGMENT : mineral, metallic or organic

(plain, metallic aspect, fluorescent, marbled, granite, etc.)

MISCELLANEOUS ADDITIVES :
Anti UV, stabilizer, plasticizer, lubricant, anti-
shrinkage, ...
Making polymers conductive

Most marketed polymers do not conduct electrical current.

Their
surface resistivity is between 1015 and 1017 ohm.

But electrical conduction can be sought for:

Antistatic effect: avoid dust deposition,

bonding of plastic bags, etc.
A reduction in surface resistivity during
a few weeks or a few months may be sufficient.

- Dissipation of electrostatic charges:

it is obtained with dissipative materials and
drivers that prevent electric shock
and dissipate the loads resulting from
high speed.

Electromagnetic shielding: materials are needed

with very low volume resistivity (1 ohm.cm).
Standards must be met to limit emissions
electromagnetic products of manufactured products.
4. The nature of the fibers and
reinforcements
The reinforcements help improve the mechanical strength and rigidity of
composite materials and come in filamentary form, ranging from elongated
particle to continuous fiber which gives the material a directive effect.

They are characterized by:

• the nature of the fiber
• the architecture of the reinforcement.
4. The nature of the fibers and
reinforcements

GLASS Good compromise "properties / price" (2 € / kg)

Flexible
E, R or D glass

CARBON Excellent features

Carbon HR, THR, HM, THM, ...
High price (20 to> 150 € / kg)

KEVLAR Aromatic polyamide

Excellent tensile / density ratio
Low in compression, is difficult to machine (water jet)
Flexible variant: bulletproof vest, rope, etc.

POLYETHYLENE High molecular mass HDPE

Limited properties, but light (d = 0.9)
Competition Kevlar
4. The nature of the fibers and
reinforcements

Indicative comparative table (*)

Fibre E (*) max Strain density dilatation conductivity

MPa MPa % m/m.°K W/m.°K
0° / 90°

Glass E 73 000 >3000 4 2.54 5 / 5 1

Carbon HR >230 000 >3500 1.5 1.80 3 / 5 100

Carbon HM >350 000 >2500 0.5 1.85 -0.5 / 30 180

Carbon THM 650 000 >1800 0.2 1.90 0.1 / 20 520

Aramide 49 124 000 >2500 2.5 1.45 -6 / 66 3

Polyéthylène > 80 000 >2500 4 0.97 10 / 100 0.2

(*): order of magnitude which depends on the reference, the number of fibers in the
roving, ...
4. The nature of the fibers and Fibers = in what form?
reinforcements
CUT FIBERS in bulk

ROVING, WICK tex = g / km

NONWOVEN (g / m²) matt (> 100 g / m2)

or veil (<100 g / m2)

FABRIC (g / m² and weave) Canvas, Satin, Twill, ± 45, braid, 3D, ...
 4. The nature of the fibers and
reinforcements

8 satin

Carbon
Satin weave fabrics are much more
deformable than canvas or taffeta. This
deformability is all the greater as the
weave ratio is high. Good mechanical resistance
8 satin fabrics, very deformable, are the Little deformable
most commonly used, especially for
Twill 2 * 2: the most used
Glass complex shapes.
Innovative fabric
1. Extrusion on fiber and after weawing (CARBOSTAMP
SOFICAR / TORAY CFE)

20
1. Extrusion on fiber and after weawing (CARBOSTAMP
SOFICAR / TORAY CFE)

21
2. Powder on fabric (Pi preg de PORCHER INDUSTRIES)

22
2. Powder on fabric (Pi preg de PORCHER INDUSTRIES)

23
2. Powder on fabric (Pi preg de PORCHER INDUSTRIES)

24
2. Powder on fabric (Pi preg de PORCHER INDUSTRIES)

25
Thermostamping : basic principle

26
 Thermomecanic Analysis of PA12/CF composite
Heating 3 compressed layers of Carbostamp Heating 3 compressed layers of Pipreg

Rectangular torsion

carbostamp 3plis 30°C T2 0.05% vers 250°C 1rds 2degmin pipreg3157 pa12 15 deg vers 250°c 2degmin 1 rds

1010
Température 1010 100
Fusion =165°C Température
Fusion =175°C
Tg =45°C
10
9
109
G" ( )

G" ( )
Tg =52°C
[Pa]

[Pa]
-1
10
G' ( )

G' ( )
[Pa]

[Pa]
8
10 108

107 107 10-2

20.0 40.0 60.0 80.0 100.0 120.0 140.0 160.0 180.0 200.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0 160.0 180.0
0.0 200.0
Temp [°C] Temp [°C]

2°C/min & 1 rad/s

27
Thermomecanic Analysis of PA12/CF composite

cristallisation
@ 150°C
Pipreg

- 5°C/min & 2 rad/s

28
 Processing CARBOSTAMP

Colling under
pressure
Effect on fiber
width

29
 Processing PI-PREG

Colling under
pressure
Effect on fiber
width

30
 Processing CARBOSTAMP
Plaque de carbostamp (260°C presse puis refroidissement sous poids de 5 Kg)
260 10

0
220

VITESSE DE REFROIDISSEMENT (°C/min)

-10
TEMPERATURE (°C)

180
-20

Cooling ramp
140 -30

-40
100

Température -50

60
Cooling
Vitesse deramp
refroidissement -60

20 -70
0 60 120 180 240 300 360 420 480 540
temps de refroidisement (s)

31
 Optimisation of processing thermoplastic composites

Processing and mechanical properties evaluation of

a commingled carbon-fibre/PA-12 composite, McDonnell, P; McGarvey, KP;
Rochford, L; COMPOSITES PART A-APPLIED SCIENCE AND
MANUFACTURING 32, 7 : 925-932 (2001).

The composite consists of a 2*2 twill fabric composed of 58% carbon fiber from Teho
Tenax in a polyamide matrix 12. The temperature rise is made at 6.5°C/min. The
pressure is maintained during cooling with the activation of water circulation in the lower
and upper plateaus to obtain an average speed of 10°C/min. The PA12/FC composite is
released when the temperature reaches 60°C. Three implementation parameters have
been modified to optimize the mechanical performance of the 18 thermoplastic
composite plates prepared by thermocompression: the moulding temperature (200°C,
220°C and 240°C), the pressure (4 and 8.6 Mpa) and the moulding time at the set
temperature (2, 5 and 10 min).

The results of the traction and compression tests are gathered in the following table.

32
 Questions

1) Provide definition, illustration and benefits of twill fabric 2*2

2) Interpret results of mechanical tests.

3) Draw the profile (temperature, time pressure) for the optimized

plate. Conclusions.

4) Evaluate the production of plates using this method of

implementation for a single-footprint mould and for a working
day (8h).

5) Propose one or more possible optimizations to reduce the cycle

time, by describing by the same your validation method.

33
Results of mechanical characterization of the several PA12/CF composites
34
Draw the profile (temperature, time pressure) for the optimized plate.

35
5. Procédés de production de profilés

5.1

36
5.1.1

37
38
5.1.2

5.1.3

39
5.2

5.2.1

40
5.2.2

5.2.3

41
Pultrusion de fibres de verre continue

42
De l’extrusion vers la pultrusion

43
Exemples de pièces pultrudées

44
5.4 Comparaison des différentes procédés de mises en œuvre de profiles fibres longues

45