Title: Modeling of Over molded Discontinuous-Continuous Fiber Composites

Authors: Abdallah Barakat, Georges Chahine, Sanjita Wasti, and Uday Vaidya

DOI: 10.33599/nasampe/s.24.0282

Abstract: The focus of this work was to evaluate performance and synergy of continuous-discontinuous compression over molded carbon fiber thermoplastic composites. Overmolding via injection and compression molding is becoming increasingly used to enhance thermomechanical performance of composites in automotive, transportation and related sectors. In the case of discontinuous fiber composites, understanding fiber orientation and distribution is crucial for evaluating the thermomechanical performance of the composite. A combination of Moldex3D in conjunction AlphaSTAR Genoa/MCQ was used to predict process induced flow in injection and structural performance in static and fatigue loading. The various aspects studied included evaluation of fiber transportation, orientation, and distribution, thermomechanical warpage, and shrinkage among others. Attention was also given to the interface between the discontinuous and continuous fiber constituents to evaluate onset of debonding and material failure. Experimental evaluations include X-ray CT, high resolution microscopy, nanoindentation and interlaminar tensile strength (ILT). Another critical aspect in modeling discontinuous fiber involves understanding the migration of fibers in polymeric flows, during the processing of composite material. A case study incorporating overmolding of discontinuous with continuous fiber reinforcement related to an automotive part will be included. The presentation will cover comprehensive modeling and experimental findings. The work is conducted in part through IACMI-The Composites Institute. This work commemorates Dr. Frank Abdi for his contribution to composite innovations and simulations that has been recognized by R&D 100 award in 2015.

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Conference: SAMPE 2024

Publication Date: 2024/05/20

SKU: TP24-0000000282

Pages: 18

Price: $36.00