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Abstract
Much potential and interest exists for the fast processing of lightweight, inexpensive composite preforms in automotive and other transport
applications. As a thermoplastic matrix is more suitable for mass production with short cycle times, a novel cost-effective glass fibre
reinforced thermoplastic textile preform is developed. Weft-inserted warp knitting is used to produce this textile preform containing both
the reinforcing fibres and the thermoplastic matrix material as split-film ribbons. The aim of the work is to establish a useful processing
technique and to control those parameters which lead to the production of good quality composite parts. The current study is specifically
directed at determining the feasibility of the GMT-based cold pressing technique for the manufacturing of this new type of thermoplastic
composite. An experimental design method is used to develop a statistical model which gives response surfaces of the effects of the
processing parameters on the mechanical performance of the final composite part. Processing variables are ranked in order of importance
to determine the optimal processing window. An economical comparison with the use of long fibre reinforced GMT mats proves the costefficiency of this new continuous reinforced thermoplastic composite. 1999 Elsevier Science Ltd. All rights reserved.
Keywords: Thermoplastic
1. Introduction
Enhanced safety standards and extended luxury demands
have tremendously increased the weight of vehicles. Fibre
reinforced composite materials offer, besides Al and Mg, a
significant lightweight potential in structural body parts of
vehicles [1]. Due to some severe disadvantages of thermoset
composites, such as long production times, limited recyclability, constrained storage time as well as storage requirements, interest in thermoplastic composites has developed
recently [2]. Despite a promising cost decrease when using a
thermoplastic matrix, the raw material price level is as yet
far from that of competing lightweight metals. A growth in
the use of thermoplastic composites currently depends on
further reduction of the manufacturing cost and optimisation
of the part performance. A decrease in the fabrication cost of
thermoplastic composite parts can be obtained if the separate impregnation step is eliminated, by means of a dry
impregnation [1]. Amongst other techniques such as
powder impregnation, melt and solvent impregnation, film
stacking and fibre co-mingling [8,17,18], the use of textile
preforms has recently been studied. Moreover, the difficult
* Corresponding author. Tel.: 32-16-32-11-95; fax: 32-16-32-19-90.
E-mail address: sofie.baeten@mtm.kuleuven.ac.be (S. Baeten)
1359-835X/99/$ - see front matter 1999 Elsevier Science Ltd. All rights reserved.
PII: S1359-835 X( 98)00 173-0
668
Split-film is a special term for a continuous thermoplastic film that has been cut lengthwise into tapes of
small cross section. The resultant yarn is much less
expensive than conventional (i.e. spun) fibres, but is
nevertheless well-suited to classical textile operations.
Warp knitting of split-film only, has been known for a
long time as a favourable technique to produce low-cost
net-type textile structures in large volumes. Warp knits
also exhibit a great drapability. For this reason it was
intended to combine warp knitting of split-films with
weft-inserted reinforcement fibres to obtain a non-crimp
fabric. Hence, weft-inserted multi-axial warp knitting is
chosen for its low production cost to produce the SPLITWARPKNIT thermoplastic textile preform containing
both non-crimp reinforcing fibres and thermoplastic
matrix ribbons (Fig. 1). It allows for non-impaled knitting where the loop formation is achieved without needling through the fabric and a degradation of the
mechanical properties due to a premature damage of
the reinforcing fibre bundles is avoided. Instead, the
weft-inserted yarns are placed parallel to the needle
row in a one by one manner. The split-films are either
used as warp knitting yarn (see Fig. 1: co-knitted structure)
where the glass fibres are inserted along the weft and warp
direction (bi-axial textile) or they are inserted in the straight
yarns along with the reinforcement rovings. The loops,
hence, exclusively consist of a binding yarn (PET yarn)
(Fig. 1: hybrid mono-axial structure).
The merit of this new split-warpknit textile is that a
composite part can eventually be made in only one step
directly from the dry textile preform, without the further
addition of matrix material. No intermediate production
steps, which prolong the cycle time, should be necessary.
The main issue during the production of thermoplastic
composites is, however, the impregnation of the reinforcing
fibres by the highly viscous thermoplastic matrix. During
impregnation, the polymer matrix has to flow through
closely packed fibre bundles and wet-out the individual
fibres, while high temperature and pressure is applied. The
impregnation time is controlled by the velocity and the ease
of flow of the thermoplastic matrix to guarantee a good
adhesion between the fibre and the matrix. Different
preforming techniques have indeed been developed to intermingle the fibre and the matrix in a dry textile structure to
reduce the flow distance and decrease the impregnation
time. Co-mingled yarns where glass fibres and thermoplastic polymer yarns are brought together in one bundle (cf.
Twintex yarn from Vetrotex) are nowadays of increasing
interest. The new split-warpknit structure comprising the
reinforcing glass fibres and the thermoplastic PP split-film
ribbons in one hybrid yarn, held together with a nonmeltable PET binding yarn (see Fig. 1) also results in an
improved impregnation homogeneity and good mechanical
properties. The split-warpknit textile is hence competitive
with other commercial materials already available on
the market [10,19].
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Fig. 1. Mono-axial hybrid split-warpknit thermoplastic textile preform (weft-inserted). Bi-axial co-knitted split-warpknit thermoplastic textile preform (weftand warp-inserted).
The advantages of this class of thermoplastic split-warpknit textile preforms can be summarised [6,7]:
low production cost of the textile structure because thermoplastic ribbons are used;
preform shows a good drapability: complex parts can be
made in a one step process from dry textile to final
composite part;
increased mechanical properties of the composite due to
the non-crimp textile structure;
one textile structure is composed of different layers, with
different orientations of the reinforcing fibres. It is hence
a multi-layer, multi-axial (weft and warp insertion of
reinforcing glass fibre bundles) preform which enhances
the part cost efficiency;
short cycle processing time is possible: this thermoplastic
textile preform is processable with the GMT-based cold
pressing technique, allowing for a fast production using
commercially available moulding equipment;
as the hybrid yarn structure determines the homogeneity
of the distribution of the reinforcing fibres in the polymer
matrix and thus the mechanical performance, a good
composite part can be made.
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Fig. 2. Overview of the GMT-based production technique: one step process from dry textile preform to final composite part.
Cold pressing
mould temperature
consolidating pressure
holding time at pressure
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Fig. 3. Influence of the holding time on the tensile modulus and strength of cross ply split-warpknit laminates of the bi-axial co-knitted split-warpknit.
E45
21 nxy
where Gxy is the in-plane shear modulus (in GPa), E45 is the
tensile modulus achieved during a tensile test of a ^45
laminate (in GPa) and nxy is the Poisson coefficient.
No shear strength is determined due to a plastic yielding
of the thermoplastic PP matrix. In the ^45 tensile test, both
the longitudinal and transversal strains have to be measured.
The derivation of the formula for a 45 tensile test is
presented in Ref. [20].
During a first feasibility study, the relative importance of
the different cold pressing parameters (temperaturepressuretime) on the tensile and shear behaviour of cross ply
laminates of the bi-axial co-knitted split-warpknit textile is
hence determined. Also the influence of the preheating
temperature was further considered [12].
It was proved that the mould pressure does not affect the
tensile modulus and strength of the cross ply [0,90] splitwarpknit composite laminate. Probably there will be a minimum pressure needed to make the highly viscous thermoplastic matrix flow through the closely packed glass fibres
and to guarantee a sufficient wet-out of the glass fibre
bundles by the PP. This minimum could, unfortunately,
not be determined with the actual press, which has a minimum pressure of 0.8 bar.
The influence of the holding time at high pressure on the
tensile properties of the cross ply [0,90] is negligible once a
certain minimum time (^30 s) is reached (Fig. 3). Because
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Fig. 4. Temperature profile of the bi-axial split-warpknit textile, when placed in the mould (laminate thickness 2.53 mm).
Fig. 5. Influence of the preheating temperature on the tensile modulus and strength of a symmetric cross ply [0,90] laminate of the bi-axial split-warpknit
textile.
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Fig. 6. The influence of the preheating temperature on the 45 tensile modulus E45 and shear modulus Gxy of a cross ply laminate of the bi-axial split-warpknit,
tested under 45.
4.2.2.1. Screening. During the screening phase, the different processing parameters were set at two levels in an L16
array (fractional factorial design), performing 16 experiments (see Table 1). This set-up even allows for the evaluation of the significance of first-order interactions between
the different processing parameters:
pressure and holding time
pressure and mould temperature
holding time and mould temperature
preheating time and holding time
preheating time and mould temperature
preheating temperature and mould temperature
preheating time and preheating temperature
The optimisation study is, however, performed for the
mono-axial GF/PP split-warpknit with a PET binding yarn
(see Fig. 1), because this hybrid structure shows superior
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Table 1
Parameter settings of the screening phase
Low
High
220
60
2.2
50
30
260
180
45
125
120
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Fig. 8. Effect of the parameter settings on the flexural modulus of a split-warpknit laminate.
Fig. 9. Effect of the parameter settings on the bending strength of a split-warpknit laminate.
Fig. 10. (a) Interaction between the mould temperature and pressure on the flexural modulus. (b) Interaction between the mould temperature and pressure on
the flexural strength. (c) Interaction between the preheating temperature and time on the flexural modulus. (d) Interaction between the preheating time and
holding time on the flexural strength.
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Table 2
Parameter settings of the first optimisation step (preheating temperature
260C and mould temperature 125C)
Table 3
Settings for holding and preheating time during the second optimisation
step
Low
High
180
45
180
240
60
240
160
140
120
100
276
312
348
384
Fig. 11. The influence of pressure on the bending performance of a hybrid split-warpknit laminate.
Fig. 12. The flexural strength as a function of holding and preheating time
for a hybrid split-warpknit laminate.
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Fig. 13. Elliptical parameter array for the composite design method.
Fig. 14. Modelled surface for the flexural modulus (composite design): interaction between preheating and holding time.
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Fig. 15. Modelled surface for the flexural strength (composite design): interaction between preheating and holding time.
intra-bundle impregnation
inter-bundle impregnation
After consolidation, the individual fibre bundles are still
visible despite the temperature and pressure. The higher the
impregnation pressure and the longer the time, the more
homogeneous the fibre distribution within the fibre bundle
will be [18,21,22]. The impregnation steps hence consist of
two main steps [22].
Initially separated fibre bundles are flattened out and
move towards each other when pressure is applied.
Fig. 16. Correlation between the tensile and flexural modulus for the split-warpknit laminates (see Table 4).
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Fig. 17. Correlation between the tensile and flexural strength for the split-warpknit laminates (see Table 4).
Table 4
Parameter set of the laminates, tested in tension
Type
1-GMT
2-GMT
3-GMT
4-GMT
5-GMT
6-GMT
7-GMT
8-GMT
9-classical
180
180
180
240
180
180
380
610
260
220
220
260
260
260
260
260
2.2
45
45
60
45
45
60
60
20
50
50
125
125
125
125
125
125
240
30
30
120
180
120
120
100
70
300
Fig. 18. Non-homogeneous fibre distribution and matrix rich zones for a
non-optimal GMT cold pressing technique.
Fig. 19. More homogeneous fibre distribution for optimal GMT cold pressing cycle.
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This phase already starts during the conductive preheating where low pressure is applied to avoid the uncontrolled shrinkage of the PP ribbons. If the temperature
reaches the melt temperature of the thermoplastic matrix,
the polymer melts and tends to separate out of the
bundles to fill the spaces between them (inter-bundle
impregnation). The border of the reinforcing fibre is
clearly visible.
Consequently, the molten matrix infiltrate in the fibre
bundles and wet-out the individual fibres under the
applied pressure.
Because a cold pressing is applied during the GMT technique, the viscosity of the thermoplastic matrix decreases
very rapidly and a full melt-impregnation of the individual
fibres is hence not possible. The border of the fibre bundles
remains clear, resulting in a less homogeneous fibre distribution where matrix rich zones separate non-fully wetted
fibre bundles (Figs 18 and 19). Moreover, the non-meltable
stitches act as a periodic screen to the bulk flow of the
thermoplastic matrix between the fibre bundles. For this
reason, the fibre distribution is even for the optimal classical
matched-die moulding process not perfectly homogeneous
(Fig. 20).
Table 5
Comparison of the mechanical properties and void content for the GMT
cold pressed and the classical matched-die moulded laminates
Matched-die
moulding
GMT cold
pressing
38.5
60.0
1.5
6.8
99.4
17.0
317.2
32.0
63.0
5.0
5.6
91.0
13.6
268.4
Material
Price index
Remarks
PP polymer
PP filaments
PP film
100
450
250
Granulates
Glass fibres
Twintex-PP/glass
200
280
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Table 7
Price estimation based on material cost of September 97 and bobbin technology for the split-warpknits
Material
Weight (g/m 2)
Width (cm)
Reinforcement
Vol.%
Cost (ECU/kg)
Split-warpknit
Twintex warpknit
673
700
130
130
Uni-axial
Uni-axial
52
50
4.2
6.7
Acknowledgements
This research is suppported by the European Community
Research Programme Brite-Euram, Project no BE7256-93,
Contract number BRE2-CT94-0552. The authors gratefully
acknowledge the financial contribution by the commission
and the contribution of the different partners, especially
Prof. K. Schulte (TUHamburg-Harburg, Germany), Walter
Zah (Karl Mayer, Germany), Dr Edith Mader (Institut fur
Polymerforschung, Germany), Carl-Hakan Andersson
(Lund University, Sweden), Kjell Eng (Engtex, Sweden).
Part of this research has been financed with a specialisation
grant of the Flemish Institute for the Promotion of Scientific
and Technological Research in Industry (IWT). This text
presents research results of the Belgian programme on Interuniversity Poles of Attraction initiated by the Belgian State,
Prime Ministers Office, Science Policy Programming. The
scientific responsibility is assumed by its authors.
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