JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 57

Fine-tuning the compounding process The idea is to transfer the higher performance of HM fibres as much as possible to the thermoplastic compound. Unfortunately, this is difficult given the typical conditions of the extrusion process, where very high shear stresses, relative speed and pressure can lead to severe strand breakage, compromising the efficiency of the stress transmission mechanism that occurs at the fibre-matrix interface. In extrusion and injection moulding, the length of reinforcing fibres must be kept as high as possible. Lati technicians fine-tuned the extrusion parameters and optimized the machine layout (in particular the carbon-fibre feeding position along the extruder barrel) and the plasticizing screw profile and speed. Solutions were sought for problems that cropped up during the process, specifically: • fibre bundle build-up (due in part to strand length) during both extrusion and moulding processes, hindering the melt flow and leading to polymer carbonization, machine jamming and parts failure; • excessive melt viscosity – HM fibres were added up to 45% by weight introducing a relevant volume fraction of non-melting fillers. Melt viscosity needed to be kept strictly under control to avoid poor moulding and material degradation due to friction and shear; • poor reinforcement dispersion, making it necessary to achieve uniform carbon fibre distribution in the matrix to ensure consistent mechanical properties between moulded parts. The resulting HM family now includes three new commercially available compounds, all 40% reinforced with HM carbon fibre: • PPS-based LARTON K/40 HM; • PPA-based LARAMID D K/40 HM; • high-fluidity PEEK-based LARPEEK 10 K/40 HM. function of the chosen matrix. At 49,000 MPa, the elastic modulus of the PPS grade, for example, is comparable to that of metals. Fig. 3: Elastic modulus values (MPa). Such values guarantee much stiffer behaviour of structural parts such as brackets, flanges, shafts, and levers, allowing remarkably lower displacements of geometric features under load. This advantage may lead to plastic parts that, just like composites, can be considered as stiff as metal alloys for many engineering purposes, promoting both metal replacement and introduction of polymers in new, demanding projects. As a comparison, PA66 reinforced by 50% glass fibre, which is the most popular structural compound available on the market, turns out to be three times “softer” than the best HM grade. Table 2: Elastic modulus comparaison. Compound PA66 PPS PPA PEEK PA66 PPS PPA PEEK PEEK PPA PPS 50% glass fibre 50% glass fibre 50% glass fibre 50% glass fibre 30% high-tenacity carbon fibre 30% high-tenacity carbon fibre 30% high-tenacity carbon fibre 30% high-tenacity carbon fibre 40% high-modulus carbon fibre 40% high-modulus carbon fibre 40% high-modulus carbon fibre E (MPa) 15,000 18,000 19,000 16,000 23,000 22,500 23,000 21,500 40,000 41,000 49,000 Results Benchmark tests between Lati HM structural compounds and traditional grades demonstrated the far superior performance of the HM compounds. Elastic modulus ISO-R-527 tensile tests revealed the mechanical advantages of HM compounds, with elastic modulus values well above 40,000 MPa (24,000 MPa is already a very good value for a generalpurpose thermoplastic reinforced with 30% high-tenacity carbon fibre). This value is expected to fluctuate somewhat as a No50 July-August 2009 / jec composites magazine 57

JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009

Cover
Index
Contents
- NEWS WORLDWIDE -
Companies - Innovation: the guiding principe at Hunstman
Companies - More V: operating on a practically boundless market
Companies - IDI Composites buys former Menzolit facilities
Companies - Colan Australia, threads worth their weight in gold!
Companies - DSM Composite Resins and Büfa: they finalize european joint venture agreements
Agenda of events
Equipment - Custom-coated carbide tools for improved adaptability and lower costs
- BUSINESS -
Market Survey - US demand for decking to reach 1.1 billion lineal metrs in 2013
Trends - Wood-plastic composites: markets, applications and performance costs
Human capital - A PhD student rewarded for his environmental concerns
- FEATURE -
Software - On the way to a high-tech process for high-performance applications
Process - The latest innovations to the LRTM molding process
Application - Large truck mid-roof to be manufactured in Brazil
Application - RTM part for Franch high-speed train
Production - An RTM production line with environmental credentials
Innovations - Plascore PP honeycomb infusion grade for Light RTM
Innovations - RTM compression press for manufacturing body panels
Innovations - Institut fuer Verbundwekstoffe GmbH
- USERS' PLATFORM -
Composites in the world - The Aston Martin One-77
Composites in the world - Cavalier pot
Composites in the world - Carbon fish sculptures
Composites in the world - Glass-fibre-reinforced body camera
Successful partners - An innovative reinforced profile for window frames
Application - MFG: boosting the growth of the wind energy market
Application - Blue Hawaiian Fiberglass Pool: leader in Florida
- KNOW-HOW -
Ductile prepregs - Formable aligned-fibre composite materials
Compound - High-modulus carbon fibres in super-structural compounds
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Cover
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 2
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 3
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 4
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Index
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Contents
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 7
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Companies - Innovation: the guiding principe at Hunstman
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Companies - More V: operating on a practically boundless market
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Companies - IDI Composites buys former Menzolit facilities
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Companies - Colan Australia, threads worth their weight in gold!
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 12
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 13
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Companies - DSM Composite Resins and Büfa: they finalize european joint venture agreements
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 15
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Agenda of events
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 17
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Equipment - Custom-coated carbide tools for improved adaptability and lower costs
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 19
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 20
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - - BUSINESS -
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Market Survey - US demand for decking to reach 1.1 billion lineal metrs in 2013
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Trends - Wood-plastic composites: markets, applications and performance costs
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 24
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 25
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Human capital - A PhD student rewarded for his environmental concerns
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Asia Show
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - JCM
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - - FEATURE -
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Software - On the way to a high-tech process for high-performance applications
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 29
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 30
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 31
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Process - The latest innovations to the LRTM molding process
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 33
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 34
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Application - Large truck mid-roof to be manufactured in Brazil
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Application - RTM part for Franch high-speed train
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Production - An RTM production line with environmental credentials
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 38
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 39
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Innovations - Institut fuer Verbundwekstoffe GmbH
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - - USERS' PLATFORM -
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Composites in the world - Cavalier pot
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Composites in the world - Glass-fibre-reinforced body camera
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Successful partners - An innovative reinforced profile for window frames
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 45
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Application - MFG: boosting the growth of the wind energy market
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 47
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 48
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Application - Blue Hawaiian Fiberglass Pool: leader in Florida
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 50
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - - KNOW-HOW -
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Ductile prepregs - Formable aligned-fibre composite materials
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 53
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 54
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Compound - High-modulus carbon fibres in super-structural compounds
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 56
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 57
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 58
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 59
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 60
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