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Puch, Florian; Richter, Bastian
Influence of the processing on the properties of continuous fiber reinforced thermoplastic sheets prepared by extrusion. - In: AIP conference proceedings, ISSN 1551-7616, Bd. 2884 (2023), 1, 050005, S. 050005-1-050005-14

Continuous fiber reinforced thermoplastics (CFRT) are composite materials consisting of continuous fibers and a thermoplastic matrix and offer outstanding mechanical properties, low densities, short cycle times and recyclability. CFRT can be classified into unidirectional tapes and sheets utilizing various semi-finished textiles as reinforcement. CFRT sheets are of interest for area measured products or multiaxial loads. Various discontinuous and semi-continuous methods to prepare CFRP sheets are described in the literature. All these methods either feature high cycle times or high investment costs and require double melting of the polymer, e.g., first to produce a polymer film and second to produce the CFRT sheet. An energy efficient alternative to produce CFRT sheets is extrusion, which allows to spare one melting step. A twin-screw extruder melts the polymer, which is then conveyed by a melt pump to the film extrusion dies and applied to both sides of the semi-finished textile, which is wetted and consolidated using a calendar. Due to the high melt viscosity and the line load at the calendar the major challenge is to achieve full void-free impregnation of the semi-finished textile. The mechanical properties of a CFRT sheet are determined by fiber and void volume content. Hence, the influence of the processing conditions on the fiber and void volume content as well as the mechanical properties were examined applying a parametric study of the die temperature, the haul-off speed, and the gap between the calendar rolls. The properties of the extruded CFRT sheets were compared to compression molded sheets. The fiber volume content was directly adjusted by the haul-off speed and the extruder throughput. An increasing die temperature lowers the melt viscosity and results in an increased fiber volume content. Scanning electron microscopy shows complete macro impregnation between the fiber bundles but not completely wetted individual filaments within fiber bundles.



https://doi.org/10.1063/5.0168183
Mohammadkarimi, Shiva; Neitzel, Benedikt; Lang, Maximilian; Puch, Florian
Investigation of the fiber length and the mechanical properties of waste recycled from continuous glass fiber-reinforced polypropylene. - In: Recycling, ISSN 2313-4321, Bd. 8 (2023), 6, 82, S. 1-20

This paper explores the mechanical recycling of continuous fiber-reinforced thermoplastics (CFRTPs) waste into injection molded products, focusing on the influence of recycling parameters on fiber length and mechanical properties. CFRTPs are gaining attention for their promising attributes, including weight-specific mechanical properties, short cycle times, storability, and recyclability, making them suitable for diverse applications. However, as CFRTP production rates rise, recycling strategies become crucial for sustainability. This study investigates the processability of CFRTP waste, defines size reduction conditions, and evaluates the impact of various compounding parameters such as temperature, screw speed, and fiber volume content during extrusion. The research findings indicate that higher screw speeds lead to fiber length reduction, whereas elevated temperatures result in longer fibers. Increased fiber volume intensifies interactions, resulting in shorter lengths. Additionally, the study examines the influence of injection molding parameters such as back pressure, screw speed, and initial fiber length on the resulting fiber length and mechanical properties of injection molded specimens, emphasizing the need for precise parameter control to optimize performance in recycled CFRTPs. Key findings are that increasing the initial fiber length from 260 μm to 455 μm results in an average fiber length after injection molding of 225 μm and 341 μm, respectively. This implies that longer initial fibers are more prone to breakage. Regarding the mechanical properties, increasing back pressure from 20 bar to 60 bar results in a reduction in Young’s modulus of approximately 40 MPa. Higher screw speed also reduces modulus by approximately 70 MPa due to intensified fiber-screw interactions. However, back pressure and screw speed have neutral effects on the tensile strength and the elongation at break.



https://doi.org/10.3390/recycling8060082
Lang, Maximilian; Neitzel, Benedikt; Mohammadkarimi, Shiva; Puch, Florian
Investigation on the influence of process parameters on the mechanical properties of extruded bio-based and biodegradable continuous fiber-reinforced thermoplastic sheets. - In: Polymers, ISSN 2073-4360, Bd. 15 (2023), 18, 3830, S. 1-14

The use of bio-based and biodegradable matrix materials in fiber-reinforced polymers (FRPs) is an approach to reduce the consumption of fossil resources and the amount of polymer waste. This study aims to assess the influence of the process parameters on the resulting mechanical properties of extruded bio-based and biodegradable continuous fiber-reinforced thermoplastics (CFRTPs) in the form of sheets. Therefore, the impregnation temperature during the production of PLA/flax fiber composites is varied between 220 ˚C and 280 ˚C, and the consolidation pressure, between 50 bar and 90 bar. A design of experiments approach is used. Fiber contents of 28.8% to 34.8% and void contents of 6.8% to 15.5% are determined for the composites by optical measurements. To assess the mechanical properties, tensile tests are performed. Using the evaluation software Minitab, a strong negative influence of the consolidation pressure on the tensile modulus and the tensile strength is observed. Increasing the pressure from 50 bar to 90 bar results in a reduction in the tensile modulus of 50.7% and a reduction in the tensile strength of 54.8%, respectively. It is assumed that this is due to fibers being damaged by the external force exerted onto the materials during the consolidation process in the calender. The influence of the impregnation temperature on the mechanical properties cannot be verified.



https://doi.org/10.3390/polym15183830
Richter, Bastian; Neitzel, Benedikt; Puch, Florian
Extrusion as an energy-efficient manufacturing process for thermoplastic organosheets. - In: Sheet Metal 2023, (2023), 43, S. 345-352

Organosheets combine the advantages of reinforcement fibers and thermoplastic polymers. By pairing these two materials, composites with outstanding mechanical properties and low densities can be produced. These semi-finished products can be further processed into complex and functionalized components by thermoforming or injection molding. There are a number of different manufacturing processes for continuous fiber reinforced thermoplastics (CFRT), however, most of them require long production times and recurrent melting of the polymer resulting in high energy and manufacturing costs. This study presents a novel extrusion process, that enables a continuous production of reinforced thermoplastic sheets with only one melting step. Due to the high energy efficiency and wide range of processible materials, this process shows a high potential for an economical production of CFRT. To investigate the extrusion process in more detail, the influence of the processing and the flow behavior of the polymer on the impregnation quality and the mechanical properties of the composites were studied. The results showed increasing fiber volume contents with lower polymer viscosities. Furthermore, higher die temperatures and pressures resulted in higher fiber volume contents and thus in higher mechanical properties. The experiments also revealed that a complete impregnation can currently not be achieved without an additional small double belt press due to the line load of the calender, the high viscosity of the melt and the short impregnation time.



https://doi.org/10.21741/9781644902417-43
Schober, Giovanni;
Aushärteüberwachung von Klebstoffen durch luftultraschallinduzierte und geführte Wellen. - Ilmenau, 2023. - 1 Band (verschiedene Seitenzählung)
Technische Universität Ilmenau, Dissertation 2023

Klebstoffsysteme finden zunehmend Anwendung in den verschiedensten Industriesegmenten und substituieren oder ergänzen oftmals konventionell angewandte Verbindungsverfahren wie das Schweißen und Nieten. Gleichzeitig bestehen zahlreiche, genormte Prüfverfahren, um die Aushärtung von Klebstoffen zu charakterisieren. Diese beschränken sich auf die Untersuchung von Probenkleinstmengen im Labor auf Basis von z. B. rheologischen und kalorimetrischen Verfahren. Die dabei erzielten Ergebnisse können aufgrund ungleicher Rahmenbedingungen nicht direkt auf die Gegebenheiten in einem industriellen Produktionsumfeld übertragen werden. Die zu Grunde liegenden Ursachen sind vielfältig. In den meisten Fällen ist etwa ein direkter Messzugang zum Klebstoff bedingt durch die vorhandenen Fügepartner nicht gegeben und Umgebungsbedingungen wie Temperatur und Luftfeuchtigkeit weichen gleichermaßen wie die betrachtete Menge an Klebstoff von den genannten Laborprüfungen ab. Im industriellen Umfeld kaum etabliert, aber im Stand der Technik und Wissenschaft beschrieben, sind hingegen zerstörungsfreie Methoden zur Prüfung von applizierten Klebstoffen. Zu diesen gehören beispielsweise die Terahertz-, berührende Ultraschall- und Kernspinresonanztechnik. Wesentliche Nachteile wie eine nicht berührungslose Arbeitsweise, die die Untersuchung klebriger Oberflächen behindert, eine geringe Eindringtiefe, aus der Informationen gewonnen werden können, einschränkende Anforderungen an die elektrische Leitfähigkeit der untersuchbaren Materialsysteme sowie letztlich hohe Systemkosten sind Gründe für eine geringe Anwenderakzeptanz. Diesen Verfahren steht ein neuer Prüfansatz auf Basis mittels Luftultraschall induzierter, geführter Wellen entgegen. Dieser erlaubt eine verhältnismäßig kostengünstige, wegintegrale Aushärteüberwachung von Klebstoffen über lange Strecken hinweg, ohne einen direkten Zugang zum Klebstoff zu erfordern. Die vorliegende Dissertation erforscht das Messprinzip und die damit verbundenen Vor- und Nachteile, demonstriert unmittelbar die Verfahrenseignung durch Betrachtung unterschiedlicher Klebstoffsysteme, untersucht den Einfluss wesentlicher Prüfrahmenbedingungen, zeigt Anwendungsmöglichkeiten sowie erkannte Limitationen auf und bietet anschließend Umgehungsstrategien zur Überwindung der genannten Limitationen z. B. durch Anwendung von sogenannten Pulskompressionsmethoden an.



Neitzel, Benedikt; Puch, Florian
Application of capacitive sensors and controlled injection pressure to minimize void formation in resin transfer molding. - In: Polymer composites, ISSN 1548-0569, Bd. 44 (2023), 3, S. 1658-1671

Void formation as a result of irregular resin flow at the flow front is discussed and a practical method for reducing void formation during resin transfer molding (RTM) is introduced. In this study, a sensor system is developed for in situ measurement of resin velocity inside a closed cavity. Assisted by the acquired data, a resin injection system is augmented to automatically adjust the injection pressure and achieve a uniform flow front velocity. It is proven, that the developed system is suited to monitor the resin flow front and is able to sufficiently control flow velocity of a linear flow front. Test specimen produced by this method show significantly reduced void contents in comparison to a common resin transfer molding process.



https://doi.org/10.1002/pc.27195
Neitzel, Benedikt; Puch, Florian
Optical detection of void formation mechanisms during impregnation of composites by UV-reactive resin systems. - In: Journal of composites science, ISSN 2504-477X, Bd. 6 (2022), 11, 351, S. 1-15

During the impregnation of reinforcement fabrics in liquid composite molding processes, the flow within fiber bundles and the channels between the fiber bundles usually advances at different velocities. This so-called “dual-scale flow” results in void formation inside the composite material and has a negative effect on its mechanical properties. Semi-empirical models can be applied to calculate the extent of the dual-scale flow. In this study, a methodology is presented that stops the impregnation of reinforcement fabrics at different filling levels by using a photo-reactive resin system. By means of optical evaluation, the theoretical calculation models of the dual-scale flow are validated metrologically. The results show increasingly distinct dual-scale flow effects with increasing pressure gradients. The methodology enables the measurability of microscopic differences in flow front progression to validate renowned theoretical models and compare simulations to measurements of applied injection processes.



https://doi.org/10.3390/jcs6110351
Hartmann, Robert; Puch, Florian
Development of a production process for environmentally friendly and resource-efficient molded parts consisting of load-appropriate reinforced wood-plastic composites :
Entwicklung eines Herstellungsprozesses für umweltfreundliche und ressourceneffiziente Formteile aus lastgerecht verstärkten Holz-Kunststoff-Verbunden. - In: Zeitschrift Kunststofftechnik, Bd. 18 (2022), 4, S. 203-233

Dieser Beitrag beschreibt einen Herstellungsprozess für umweltfreundliche und ressourceneffiziente Formteile aus neuartigen Holz-Kunststoff-Verbunden (HKV). Bei der Herstellung von HKV werden anisotrope mechanische Eigenschaften von langen, schlanken Holzspänen (Strands) durch deren lastgerechte Positionierung auf dreidimensionaler Werkzeugoberfläche anwendungsoptimiert ausgenutzt und umweltverträgliche duro- als auch thermoplastische Kunststoffe als Alternative zu den konventionellen formaldehyd- oder isocyanathaltigen Bindemitteln eingesetzt.



https://dx.doi.org/10.3139/O999.01042022
Hartmann, Robert; Puch, Florian
Numerical simulation of the deformation behavior of softwood tracheids for the calculation of the mechanical properties of wood-polymer composites. - In: Polymers, ISSN 2073-4360, Bd. 14 (2022), 13, 2574, insges. 25 S.

From a fiber composite point of view, an elongated softwood particle is a composite consisting of several thousand tracheids, which can be described as fiber wound hollow profiles. By knowing their deformation behavior, the deformation behavior of the wood particle can be described. Therefore, a numerical approach for RVE- and FEM-based modelling of the radial and tangential compression behavior of pine wood tracheids under room climate environment is presented and validated with optical and laser-optical image analysis as well as tensile and compression tests on pine sapwood veneer strips. According to the findings, at 23 ˚C and 12% moisture content, at least 10 MPa must be applied for maximum compaction of the earlywood tracheids. The latewood tracheids can withstand at least 100 MPa compression pressure and would deform elastically at this load by about 20%. The developed model can be adapted for other wood species and climatic conditions by adjusting the mechanical properties of the base materials of the cell wall single layers (cellulose, hemicellulose, lignin), the dimensions and the structure of the vessel elements, respectively.



https://doi.org/10.3390/polym14132574
Patschger, Andreas; Husung, Stephan; Puch, Florian; Röhnert, Felix
Wichtiger Wettbewerbsfaktor Thüringer Unternehmen. - In: Wirtschaftsspiegel, ISSN 2190-409X, Bd. 18 (2022), 1, S. 24-25