Thermoplastic Composites: Modelling Melting, Decomposition and Combustion of Matrix Polymers

In thermoplastic composites, the polymeric matrix upon exposure to heat may melt, decompose and deform prior to burning, as opposed to the char-forming matrices of thermoset composites, which retain their shape until reaching a temperature at which decomposition and ignition occur. In this work, a theoretical and numerical heat transfer model to simulate temperature variations during the melting, decomposition and early stages of burning of commonly used thermoplastic matrices is proposed. The scenario includes exposing polymeric slabs to one-sided radiant heat in a cone calorimeter with heat fluxes ranging from 15 to 35 kW/m2. A one-dimensional finite difference method based on the Stefan approach involving phase-changing and moving boundary conditions was developed by considering convective and radiative heat transfer at the exposed side of the polymer samples. The polymers chosen to experimentally validate the simulated results included polypropylene (PP), polyester (PET), and polyamide 6 (PA6). The predicted results match well with the experimental results.

Polyamide 6-Aluminum Assembly Enhanced by Laser Microstructuring

The presented work’s aim is the application of low-power laser treatment for the enhancement of interfacial micromechanical adhesion between polyamide 6 (filled with glass fiber) and aluminum. A fiber laser beam was used to prepare micro-patterns on aluminum sheets. The micro-structuring was conducted in the regime of 50, 100, 200 and 300 mm/s laser beam speeds, for both sides. The joining process was realized in an injection molding process. Metallic inserts were surface engraved and overmolded in one-side and two-side configurations. A lap shear test was used to examine the strength of the joints. Engraved metallic surfaces and adequate imprints on polyamide side were checked by optical microscope with motorized stages, and roughness parameters were also determined. Microscopic observations made it possible to describe the grooves’ shape and to conclude that a huge recast melt was formed when the lowest laser beam speed was applied; thus, the roughness parameter Ra reached the highest value of 16.8 μm (compared to 3.5 μm obtained for the fastest laser speed). The maximum shear force was detected for a sample prepared with the lowest scanning speed (one-sides joints), and it was 883 N, while for two-sided joints, the ultimate force was 1410 N (for a scanning speed of 200 mm/s).

Experimental and numerical investigation of metal-polymer riveted joints

This paper presents the modeling and analysis of the joints of metal inserts with polyamide 6 using the injection technique. Based on the conducted experiments, modeling and numerical calculations of joints were carried out for various joint configurations. Metal parts, made of steel grade DC 04, are mechanically locked with polyamide 6 (PA6) with rivets. The mechanical connection with rivets of both elements was achieved by filling the holes in the metal parts in the injection process. As part of the work, mechanical-clamp connections made of steel / PA6 were mechanically tested in a single-axis joint tensile test using appropriate tabs. The main goal was to study and numerically analyze the number of rivets and their location on the metal plate for the strength of the connector. An important element of the work was the modeling process of both the PA6 material behavior and the joint itself. As part of the experimental research, the rivet deformation was also observed using computer thermography with the use of an IR camera. The tests and simulation showed that for the sample, the polymer-metal connected with less than three rivets was destroyed by shear. On the other hand, when the polymer-metal junction was made of three rivets, the jamming mechanism was mainly related to damage to the polymer part. For these joints, the maximum values of the breaking force of the joint were obtained in uniaxial tensile and shear tests where three rivets were used. Similar values were obtained during the numerical calculations performed with the use of Abaqus software.

Macromolecular Insights into the Altered Mechanical Deformation Mechanisms of Non-Polyolefin Contaminated Polyolefins

Current recycling technologies rarely achieve 100% pure plastic fractions from a single polymer type. Often, sorted bales marked as containing a single polymer type in fact contain small amounts of other polymers as contaminants. Inevitably, this will affect the properties of the recycled plastic. This work focuses on understanding the changes in tensile deformation mechanism and the related mechanical properties of the four dominant types of polyolefin (PO) (linear low-density polyethylene (LLDPE), low-density polyethylene (LDPE), high-density polyethylene (HDPE), and polypropylene (PP)), contaminated with three different non-polyolefin (NPO) polymers (polyamide-6 (PA-6), polyethylene terephthalate (PET), and polystyrene (PS)). Under the locally elevated stress state induced by the NPO phase, the weak interfacial adhesion typically provokes decohesion. The resulting microvoids, in turn, initiate shear yielding of the PO matrix. LLDPE, due to the linear structure and intercrystalline links, is well able to maintain high ductility when contaminated. LDPE shows deformation similar to the pure material, but with decreasing ductility as the amount of NPO increases. Addition of 20 wt% PA-6, PET, and PS causes a drop in strain at break of 79%, 63%, and 84%, respectively. The typical ductile necking of the high-crystalline HDPE and PP is strongly disturbed by the NPO phase, with a transition even to full brittle failure at high NPO concentration.

Vibration and Sound Response of Glass-Fiber-Reinforced Polyamide 6 Using Microcellular-Foaming-Process-Applied Injection Molding Process

In this study, the vibration and sound response characteristics of composites produced via injection molding applied with a microcellular foaming process (MCPs) were improved. The study was conducted using PA6 and glass fiber composites, which are representative thermoplastic engineering plastics. Two types of specimens were used: a plate specimen to confirm the basic sound and vibration characteristics, and a large roof-rack specimen from an actual vehicle with a complex shape. The frequency response function curve was calculated by conducting an impact test, and natural frequency and damping ratio were measured based on the curve. The results confirmed that, in the case of a specimen manufactured through the injection molding process to which MCPs were applied, the natural frequency was lowered, and the damping ratio decreased. The degree of change in the natural frequency and damping ratio was confirmed. To determine the cause of the change in the natural frequency and damping ratio, the mode shape at the natural frequency of each specimen was measured and the relationship was confirmed by measuring the density and the elastic modulus of the composite. In addition, the usability of the specimens to which MCPs were applied was verified by conducting impact strength and tensile strength tests.

Специфика статистики упругих и деформационно-прочностных свойств высокопрочных волокон полипропилена

Regularities of statistical distributions of a complex of mechanical properties, including the module of elasticity (E), strength () and strain at break (b), high-strength industrial oriented polypropylene (PP) fibers have been analyzed using the Weibull and Gauss models based on large a wide array of measurements (50 identical samples in each series). The values of the statistical Weibull modulus (m) - a parameter characterizing the scatter of the measured values of the data arrays of E,  and b – have been estimated for the PP samples of two types: single fibers (monofilaments) and multifilament fibers consisting from several hundred single fibers. For the PP multifilament fibers, a more correct description of the distributions of E,  and b has been received both in the framework of the normal distribution (Gaussian distribution) and in the framework of the Weibull distribution in comparison with the description of such distributions for the PP monofilaments. The influence of the polymer chain conformation on the regularities of the statistical distributions of E,  and b for the high-strength oriented polymeric materials with different chemical chain structures and the correctness of their descriptions in the framework of the Gauss and Weibull models have been analyzed. For this purpose, the values of m calculated in this work for PP with a helical chain conformation have been compared with the values of m determined by us earlier for ultra-high molecular weight polyethylene and polyamide-6 with the chain conformations in the form of an in-plane trans-zigzag.

Assessment of New Composites Containing Polyamide-6 and Lead Monoxide as Shields against Ionizing Photonic Radiation based on Computational and Experimental Methods

This study aimed to introduce new composites, containing polyamide-6 (PA6) and lead monoxide (PbO), to protect against ionizing photon sources used for diagnostic and therapeutic purposes. Five composites, containing various weight percentages of PbO filler (0, 5, 10, 20, and 50%), were developed in this study. Initially, the numerical attenuation value was estimated using XMuDat program by calculating the mass attenuation coefficients at different energy levels. Next, the samples were synthesized based on the melt-mixing method in a laboratory mixing extruder, and their characteristics were determined by scanning electron microscopy (SEM), energy dispersive X-ray (EDX) analysis, X-ray diffraction (XRD), and thermogravimetric analysis (TGA). Finally, experimental radiation attenuation tests were carried out. Based on the SEM results, the acceptable filler weight percentage was up to 20%; however, substantial aggregates formation was observed at the highest weight percentage. The results of XRD analysis showed a higher tendency for crystallization by decreasing the amorphous area, while increasing the filler weight percentage. Moreover, the amount of mass loss was monitored at different temperatures, revealing that the filler incorporation improved the thermal durability of the samples. According to the radiation results, a good agreement was observed between the experimental and computational data, except when aggregates formation was substantial. According to the experimental data, by increasing the lead weight percentage from 0% (crude PA6) to 50%, the half-value layer decreased from 3.13 to 0.17 cm at an energy level of 59 keV and from 7.28 to 4.97 cm at an energy level of 662 keV. Considering these promising results, the applicability of PA6/PbO composites for protection against low- and medium-energy ionizing photon sources must be investigated in future studies.

The phase transition of polyamide 6 with pre-stretching process at different temperatures

The temperature and strain fields are two key factors in the regulation of fibrous aggregate structure. In this paper, plate specimens of polyamide 6 were prepared by compression molding method. The oriented polyamide 6 plates were systematically analyzed from aspects of mechanical properties, thermal properties, crystal structure and crystal morphology. The maximum tensile strength and elastic modulus of polyamide 6 plate appeared at 120℃. The stretching process induced the formation of a more thermal stable α-form crystals. With the increase of stretching temperature, α-form crystals transformed into γ-form crystals gradually. The crystal chips transformed into fibrils during the stretching process. The structural evolution model of materials under the temperature and strain fields was established.