Effects of Process Parameters in Thermoforming of Unidirectional Fibre-Reinforced Thermoplastics.

Process-induced defects during thermoforming are widespread problems in laminate manufacturing. The aim of this study is to describe the effects of holding time and pressure on several properties of the manufactured laminate. A design of experiments is performed, followed by an analysis of variance to examine significant effects. Subsequently, a regression model is created to predict the laminate's properties, which is also validated. A significant interaction between holding time and pressure is determined for the resulting tensile strength and elongation at break with a p-value of 1.52·10-16 and 0.02, respectively. The highest values of tensile strength and elongation at break are found for low settings of holding time and pressure. The fibre volume fraction is not affected by the process parameters. As holding time and pressure increase, significant fibre misalignment takes place, leading to a decrease of the mechanical properties. The regression model corresponds well with the validation and a tensile strength of 1049 MPa with an elongation at break of 2.3% is reached.

A Long-Term Study on the Content of Polycyclic Aromatic Hydrocarbons in Rubber from End-of-Life Tires of Passenger Cars and Trucks.

At the European level, limits have been set (REACH) for the content of polycyclic aromatic hydrocarbons (PAH) in products with rubber and plastic components that come into contact with human skin or the oral cavity. These limit values reported in Commission Regulation (EU) 1272/2013 are of particular importance for the utilization of end-of-life tires (ELT) as recycled rubber materials for consumer applications, but a suitable analytical method has not yet been specified. On the other hand, comprehensive measurement series of the PAH content of ELT materials are scarce in the context of compliance testing against this regulation and general published PAH levels in ELT materials are often based on very different analytical methods. In the present work, the PAH content of three different rubber granulates from ELT (obtained from whole truck and passenger car tires and truck tire treads) were investigated over a period of two years. The Grimmer method was used for PAH profile analysis, which in terms of extraction intensity and sample preparation not only meets the requirements for a reliable determination of the EU priority PAH, but in addition covers a more comprehensive PAH profile. A total of 26 different PAH compounds, including the 8 EU priority PAH (REACH) and the 16 U.S. EPA priority PAH, were analyzed and their variations over time were examined to obtain reliable current data for PAH content in rubber granulates produced from ELT.

Processing and Mechanical Properties of Highly Filled PP/GTR Compounds.

Ground rubber from automobile tires is very difficult to recycle due to the cross-linking of the macromolecules and thus the lack of thermoplastic properties. The research consisted of assessing the processing possibility via the injection of highly filled PP/GTR compounds modified with 1.5 wt.% 2.5-dimethyl-2.5-di-(tert-butylperoxy)-hexane. GTR dosing ranged from 30 wt.% up to 90 wt.%. The evaluation of the processing properties of the obtained materials was carried out on the basis of the melt flow index test results and the signals recorded during processing by the injection molding by temperature and pressure sensors placed in the mold. The influence of the applied modifier on the changes in the mechanical properties of PP/GTR was determined with hardness, impact and static tensile tests. Moreover, thermal properties were obtained by the differential scanning calorimetry method. It has been found that it is possible to efficiently process compounds with high GTR content using injection molding. The presence of the filler allows to significantly reduce the cooling time in the injection mold and thus the time of the production cycle. It has been confirmed that 2.5-dimethyl-2.5-di-(tert-butylperoxy)-hexane modifies the rheological properties of PP and thus the PP/GTR composition. The lower viscosity of the matrix results in a more accurate bonding with the developed surface of the GTR grains, which results in better mechanical properties of the rubber-filled polypropylene.

Quasi-Static and Fatigue Properties of Thermoset Sandwiches with 3D Continuous Fibre Reinforced Polyurethane Foam Core.

Innovative materials for substituting metals are required to reduce the mass of moving components. This decreases the CO2 emissions of overall systems. A thermoset sandwich for high mechanical properties and thermal insulation is presented in this paper. It has an innovative 3D continuous reinforced core, which allows the optimisation of the substance exploitation by wide-ranging possibilities of fibre orientation. This was demonstrated with three sandwich variants. The reference had no core reinforcement and the other two were reinforced with different spacer fabrics. The process chain for the manufacturing consists of Structural Reaction Injection Moulding (SRIM) and Vacuum Assisted Resin Transfer Moulding (VARTM). Significant increases in absolute as well as specific characteristic values were demonstrated by the reinforcement in a compression and bending test. It was also shown that quasi-static characteristic values under fatigue loading are maintained to a greater extent with the core reinforcement. The sandwich material was applied as a floor assembly for a snow groomer. The design was tailor-made for the mechanical, thermal and acoustic requirements. This proved the transferability of the process chain for manufacturing samples to the production of large-volume components with complex geometry.

Adjustment of Mechanical Properties of Medium Manganese Steel Produced by Laser Powder Bed Fusion with a Subsequent Heat Treatment.

Medium manganese steels can exhibit both high strength and ductility due to transformation-induced plasticity (TRIP), caused by metastable retained austenite, which in turn can be adjusted by intercritical annealing. This study addresses the laser additive processability and mechanical properties of the third-generation advanced high strength steels (AHSS) on the basis of medium manganese steel using Laser Powder Bed Fusion (LPBF). For the investigations, an alloy with a manganese concentration of 5 wt.% was gas atomized and processed by LPBF. Intercritical annealing was subsequently performed at different temperatures (630 and 770 °C) and three annealing times (3, 10 and 60 min) to adjust the stability of the retained austenite. Higher annealing temperatures lead to lower yield strength but an increase in tensile strength due to a stronger work-hardening. The maximum elongation at fracture was approximately in the middle of the examined temperature field. The microstructure and properties of the alloy were further investigated by scanning electron microscopy (SEM), hardness measurements, X-ray diffraction (XRD), electron backscatter diffraction (EBSD) and element mapping.

Monitoring the Structural Health of Glass Fibre-Reinforced Hybrid Laminates Using Novel Piezoceramic Film.

This work investigates a new generation structural health monitoring (SHM) system for fibre metal laminates (FML) based on an embedded thermoplastic film with compounded piezoceramics, termed piezo-active fibre metal laminate (PFML). The PFML is manufactured using near-series processes and its potential as a passive SHM system is being investigated. A commercial Polyvinylidene fluoride (PVDF) sensor film is used for comparative evaluation of the sensor signals. Furthermore, thermoset and thermoplastic-based FML are equipped with the sensor films and evaluated. For this purpose, static and dynamic three-point bending tests are carried out and the data are recorded. The data obtained from the sensors and the testing machine are compared with the type and time of damage by means of intelligent signal processing. By using a smart sensor system, further investigations are planned which the differentiation between various failure modes, e.g., delamination or fibre breakage.

Numerical Studies of the Viscosity of Reacting Polyurethane Foam with Experimental Validation.

Products made of polyurethane foam are manufactured by the chemical reaction of various low-viscosity raw materials and additives. The diversity of different formulations to meet the requirements of the market makes the characterization of their processing and flow properties important for a simple and error-free production. The modeling and simulation of such processes are equally of great importance. This provides additional findings without the expense of real tests and makes it easier to design components. The work described in this paper was carried out against this background. An experimental setup using a rheometer was developed to determine the flow and curing properties of reacting polyurethane foam reproducibly with comparable expansion conditions to industrial processes. The experiment was mathematically modelled to investigate the rheology of reacting polyurethane foams. The mathematical framework consists of coupled, non-linear, partial differential equations for the dynamics and the heat transfer processes in the system. These are solved numerically in 3D using finite volume techniques under adequate physical conditions. The accuracy of two viscosity laws according to the state of the art and their novel combination were investigated in this context. The proposed viscosity model of this study provides accurate results compared to the experiment.

Sulphur-doped porous carbon from a thiophene-based twin monomer.

Sulphur-doped carbon was synthesized using a thiophene-based twin monomer. While tetra(thiophene-2-ylmethoxy)-silane can be converted into sulphur containing nanocomposites, which lead to microporous sulphur-doped carbon, it is possible to produce additional mesopores by the use of templates. Thus, a variety of sulphur-doped carbon materials with tailored pore texture are available.