Get This Paper

Overmolding of Textile Grade Carbon Fiber Tape and Bamboo Fiber Polypropylene Composites


Title: Overmolding of Textile Grade Carbon Fiber Tape and Bamboo Fiber Polypropylene Composites

Authors: Sanjita Wasti , Benjamin Schwartz , Pritesh Yeole , Georges Chahine , Halil Tekinalp , Soydan Ozcan , Merlin Theodore , Jaydeep Kolape , Uday Vaidya

DOI: 10.33599/nasampe/c.22.0082

Abstract: The trend of using natural fiber composites is increasing rapidly due to the growing environmental concerns and increased awareness on sustainability. However, due to the lower strength of natural fibers (95- 1600MPa) compared to synthetic fibers (2000-4000 MPa), high moisture absorption rate, variation in the fiber properties, and lower processing temperature range limit its applications. This study advances the concept of overmolding of bamboo fiber-polypropylene (BF-PP) composites with unidirectional and 0/90 textile grade carbon fiber (TCF) tape. BF-PP composites were processed using extrusion compression molding (ECM) technique. TCF tape was produced on a thermoplastic polymer impregnation line. Mechanical and morphological properties of overmolded hybrid composites were studied. These studies attempted to evaluate the interface between the BF-PP and the TCF thermoplastic tape. Flexural strength and flexural modulus of BF-PP composites increased by ~152 % and ~164 % respectively by overmolding BF-PP with unidirectional TCF tape; and by ~53 % and ~54 % respectively on overmolding 0/90 TCF thermoplastic tape. Scanning electron microscopic (SEM) images of the TCF tape overmolded BF-PP composites exhibited good interfacial bonding. The presentation will cover the manufacturing concept, process trials, resulting properties and mechanisms. This study is part of the broader sustainability program in collaboration with the Oak Ridge National Laboratory and IACMI-The Composites Institute.

References: [1] Kore S, Spencer R, Ghossein H, Slaven L, Knight D, Unser J, et al. Performance of hybridized bamboo-carbon fiber reinforced polypropylene composites processed using wet laid technique. Compos Part C Open Access 2021;6:100185. [2] Li M, Pu Y, Thomas VM, Yoo CG, Ozcan S, Deng Y, et al. Recent advancements of plant-based natural fiber–reinforced composites and their applications. Compos Part B Eng 2020;200. [3] Gholampour A, Ozbakkaloglu T. A review of natural fiber composites: properties, modification and processing techniques, characterization, applications. vol. 55. Springer US; 2020. [4] Sanjay MR, Madhu P, Jawaid M, Senthamaraikannan P, Senthil S, Pradeep S. Characterization and properties of natural fiber polymer composites: A comprehensive review. J Clean Prod 2018;172:566–81. [5] Wang BJ, Young W Bin. The Natural Fiber Reinforced Thermoplastic Composite Made of Woven Bamboo Fiber and Polypropylene. Fibers Polym 2021;0:1–9. [6] Lotfi A, Li H, Dao DV, Prusty G. Natural fiber–reinforced composites: A review on material, manufacturing, and machinability. J Thermoplast Compos Mater 2021;34:238–84. [7] Alwekar S, Yeole P, Kumar V, Hassen AA, Kunc V, Vaidya UK. Melt extruded versus extrusion compression molded glass-polypropylene long fiber thermoplastic composites. Compos Part A Appl Sci Manuf 2021;144:106349. [8] Dhakal HN, Sain M. Enhancement of mechanical properties of flax-epoxy composite with carbon fibre hybridisation for lightweight applications. Materials (Basel) 2020;13. [9] Alwekar S, Ogle R, Kim S, Vaidya U. Manufacturing and characterization of continuous fiber-reinforced thermoplastic tape overmolded long fiber thermoplastic. Compos Part B Eng 2021;207:108597. [10] Data Sheets | RESOURCES | Carbon Fiber Composite Materials | TORAY n.d. (accessed June 5, 2022). [11] Hiremath N, Young S, Ghossein H, Penumadu D, Vaidya U, Theodore M. Low cost textile-grade carbon-fiber epoxy composites for automotive and wind energy applications. Compos Part B Eng 2020;198:108156. [12] Khan H, Kaur J, Naebe M, Hutchinson S, Varley RJ. Continuous, pilot-scale production of carbon fiber from a textile grade PAN polymer. Mater Today Commun 2022;31:103231. [13] Paramasivam A, Timmaraju MV, Velmurugan R. Influence of preheating on the fracture behavior of over-molded short/continuous fiber reinforced polypropylene composites. J Compos Mater 2021;55:4387–97. [14] Matsumoto K, Ishikawa T, Tanaka T. A novel joining method by using carbon nanotube-based thermoplastic film for injection over-molding process. J Reinf Plast Compos 2019;38:616–27. [15] Yeole P, Alwekar S, Veluswamy NKP, Kore S, Hiremath N, Vaidya U, et al. Characterization of textile-grade carbon fiber polypropylene composites. Polym Polym Compos 2021;29:652–9. [16] Vaidya U, Hiremath N, Spencer R, Young S, Penumadu D, Mainka H, et al. Manufacturing Demonstration of Automotive Seat Backrest Using Sheet Molding Compound and Overmolding with Continuous Reinforcement. Appl Compos Mater 2022. [17] Wis AA, Kodal M, Ozturk S, Ozkoc G. Overmolded polylactide/jute-mat eco-composites: A new method to enhance the properties of natural fiber biodegradable composites. J Appl Polym Sci 2020;137:1–10. [18] Tian H, Yao Y, Liu D, Li Y, Jv R, Xiang G, et al. Enhanced Interfacial Adhesion and Properties of Polypropylene/Carbon Fiber Composites by Fiber Surface Oxidation in Presence of a Compatibilizer. Polym Compos 2019;40:E654–62. [19] Haghighatnia T, Abbasian A, Morshedian J. Hemp fiber reinforced thermoplastic polyurethane composite: An investigation in mechanical properties. Ind Crops Prod 2017;108:853–63. [20] Wu T, Tinkloh S, Tröster T, Zinn W, Niendorf T. Measurement and analysis of residual stresses and warpage in fiber reinforced plastic and hybrid components. Metals (Basel) 2021;11:1–23. [21] Collins C, Batista NL, Hubert P. Warpage investigation of carbon/PEEK discontinuous long fibre thin panels. J Compos Mater 2021;55:3529–37. [22] Song Y, Gandhi U, Sekito T, Vaidya UK, Vallury S, Yang A, et al. CAE method for compression molding of carbon fiber-reinforced thermoplastic composite using bulk materials. Compos Part A Appl Sci Manuf 2018;114:388–97. [23] Wang YY, Wang XQ, Li YQ, Huang P, Yang B, Hu N, et al. High-Performance Bamboo Steel Derived from Natural Bamboo. ACS Appl Mater Interfaces 2021;13:1431–40. [24] Zhang Y, Wen B, Cao L, Li X, Zhang J. Preparation and properties of unmodified ramie fiber reinforced polypropylene composites. J Wuhan Univ Technol Sci Ed 2015;30:198–202. [25] Huang X. Fabrication and properties of carbon fibers. Materials (Basel) 2009;2:2369–403. [26] Taketa I, Kalinka G, Gorbatikh L, Lomov S V., Verpoest I. Influence of cooling rate on the properties of carbon fiber unidirectional composites with polypropylene, polyamide 6, and polyphenylene sulfide matrices. Adv Compos Mater 2020;29:101–13.

Conference: CAMX 2022

Publication Date: 2022/10/17

SKU: TP22-0000000082

Pages: 12

Price: $24.00

Get This Paper