Исследование механических свойств пултрузионных термопластичных композиционных материалов (Study of the mechanical properties of pultruded thermoplastic composite materials) тема диссертации и автореферата по ВАК РФ 00.00.00, кандидат наук Минченков Кирилл Олегович

• Минченков Кирилл Олегович
• кандидат наук
• 2024

Оглавление диссертации кандидат наук Минченков Кирилл Олегович

Contents

1. Introduction

2. The state of the art

2.1. Thermoplastic pultrusion process

2.1.1. Preheater temperature

2.1.2. Temperature and geometry of the heated die

2.1.3. Cooling die temperature

2.1.4. Pulling speed

2.1.5. Pressure and pulling force

2.2. Raw materials and properties of pultruded composites

2.2.1. Tapes

2.2.2. Commingled yarns

2.2.3. Towpregs

2.2.4. Mechanical properties

2.2.5. Durability

2.3. Thermoplastic pultrusion modeling

2.3.1. Impregnation

2.3.2. Heat transfer

2.3.3. Pressure and pulling force

2.4. Application

2.5. Literature review conclusion

3. Materials and methods

3.1. Raw materials

3.1.1. Industrial tapes

3.1.2. Sheets

3.1.3. Commingled yarns

3.2. Production of tapes

3.3. Pultrusion setup

3.3.1. Strip profile

3.3.2. Rectangular tube profile

3.3.3. Channel profile

3.4. Material characterization

3.4.1. Mechanical tests

3.4.2. Microscopic observation

3.4.3. Thermal analysis

3.4.4. Surface roughness analysis

4. Effects of raw materials on thermoplastic pultruded profiles

4.1. Manufacturing of strip profile

4.1.1. Pultrusion from industrial tapes

4.1.2. Pultrusion from laboratory-made tapes

4.1.3. Pultrusion from sheet prepreg

4.2. Microscopy observation

4.3. Roughness of the surfaces

4.4. Mechanical properties

4.5. Chapter conclusion

5. Numerical analysis of the thermoplastic pultrusion

5.1. Heat transfer model formulation

5.2. Simulation of heat transfer

5.3. Modeling results

5.4. Model validation

5.5. Chapter conclusion

6. Pultruded profile for window frame structure

6.1. Numerical heat transfer analysis

6.1.1. Rectangular tube pultrusion

6.1.2. Pultrusion of channel profile

6.2. Microscopic observation of pultruded profiles

6.3. Window frame structure with thermoplastic pultruded core

6.4. Thermal analysis of window structure

6.5. Chapter conclusion

Conclusions

List of abbreviations

List of figures

List of tables

Bibliography

Acknowledgements

Введение диссертации (часть автореферата) на тему «Исследование механических свойств пултрузионных термопластичных композиционных материалов (Study of the mechanical properties of pultruded thermoplastic composite materials)»

1. Introduction

Fiber-reinforced polymer (FRP) are used in aerospace, civil engineering, energy systems and marine applications due to their high specific strength and stiffness, increased durability, and high fatigue and corrosion resistance. One of the most productive methods of manufacturing composites is pultrusion. In the pultrusion process, a fiber with polymer passes through a heated die. Inside the die, the fiber is impregnated with polymer and the composite material takes the desired shape. At the exit of the die, a glass fiber with a constant cross section is obtained. Today, most pultrusion profiles are made of thermoset polymers that do not melt when heated. The use of thermoplastic polymers in pultrusion composites will increase the impact strength of the material, make it easier to process and create welded structures due to the ability of thermoplastics to melt during the heating.

The relevance of the dissertation lies in the fact that it addresses the existing thermoplastic pultrusion challenges related to the high viscosity of the melt thermoplastics, which increases the porosity of the manufactured profiles and reduces the mechanical properties.

Extent of research topic development. Currently, profiles of complex shapes such as boxes, L-shape, I-beam, U-shape are produced by thermoset pultrusion. Thermoset composite structures have found their application in pedestrian bridges, fences, pool covers, etc. Unfortunately, thermoplastic composite profiles and structures based on them are not presented in scientific literature and engineering practice. Thermoplastic pultrusion used for prototype production of rods up to 20 mm in diameter for intended application in insulation of overhead power lines and thermoplastic strip profiles up to width of 30 mm and thickness up to 3.5 mm.

Three-dimensional mathematical models have been developed to study the process of thermoset pultrusion. These models allow to analyze resin flow and impregnation, curing and crystallization, heat transfer, pulling force, residual stresses, and shape distortion. However, in the field of thermoplastic pultrusion, only two-dimensional

models of fiber impregnation, heat transfer, pulling force, and crystallization kinetics have been presented.

Thermoplastic composite materials are considered to have inferior mechanical properties compared to thermoset materials. This is due to the challenge of impregnating the fiber with high viscosity thermoplastic polymer, which makes it difficult to achieve a high volume fraction of fiber and low porosity in the final product. To address this issue, prepregs are utilized, which involve impregnating the fiber with polymer to reduce porosity of thermoplastic profiles. However, there are few scientific studies that examine the influence of prepreg properties on the mechanical properties of pultruded thermoplastic composite materials.

The aim of the dissertation is to improve the mechanical properties of thermoplastic pultruded composite materials. To accomplish this aim, the following objectives have been solved:

• Effects of prepreg manufacturing methods on the mechanical properties of pultruded profiles are studied.

• Effects of raw materials quality (fiber volume fraction, porosity) on the mechanical properties of pultruded materials are studied.

• Mathematical model of heat transfer to analyze the influence of heated die temperature and pulling speed on mechanical properties of pultruded profiles is developed.

The scientific novelty of this thesis is summarized as follows:

• The technology for manufacturing thermoplastic tapes from commingled yarns with a fiber volume fraction of 50% for use in pultrusion has been developed. Pultruded glass fiber/polypropylene profiles made of these tapes have flexural modulus at least 37 GPa.

• A three-dimensional mathematical model was developed and validated to analyze and predict the heat transfer inside the composite material at different pulling speeds and heating temperatures.

• New structural composite channel (31 mm x 25 mm), tube (20 mm x 30 mm), and strip profiles (75 mm x 3.5 mm) were manufactured by thermoplastic pultrusion.

• New design of windows structure with reinforcing cores made of thermoplastic pultruded composites instead of steel ones was presented. The strength of window corner joint increased two times. The thermal resistance of the window structure has been increased by using a composite core.

The theoretical significance of this thesis lies in the determination of the temperature distribution inside the thermoplastic composite material during pultrusion, which effects on mechanical properties. The study also determined the effects of raw material quality on the mechanical properties of the manufactured material. The practical significance of the thesis lies in the ability to predict the optimal pultrusion process parameters for manufacturing high-quality profiles. Additionally, the study demonstrated the practical application of thermoplastic pultruded profiles in window structures, which improved strength and thermal resistance.

Research methodology and methods. The heat transfer equations within the die and material were solved using the finite element method (FEM). The melting temperatures of polymers were obtained by the differential scanning calorimetry (DSC) method. The cross section of the profiles was examined by optical and electron microscopy. Density estimation was carried out by gravimetric method. The mechanical properties of the fabricated materials were determined experimentally on testing machines according to ASTM, ISO standards.

There are following statement to be defended:

• Composite profiles made of glass fiber and polypropylene with a flexural modulus of 37 GPa have been produced by pultrusion from tapes made in the laboratory.

• Increase in pulling speed results in a reduction in flexural, tensile, and compressive strength and modulus. This reduction in mechanical properties is attributed to inadequate heating of the pultruded material, which increases the porosity.

• Three-dimensional mathematical model of heat transfer of thermoplastic pultrusion is developed for prediction of pulling speed and heating temperature to manufacture composite material with high mechanical properties.

• The developed heat transfer model was used to predict pultrusion parameters for the production of structural profiles, which were used in the window structure as reinforcing core.

The validity and reliability of the results are ensured using a mathematical model is based on physics equations that are solved using finite element method. Model allows to predict pultrusion process parameters such as pulling speed, heating temperature based on the profile shape. The results of this work are in agreement with experimental data obtained during the manufacturing of various pultrusion products. The reliability of the work is confirmed by the accuracy of mathematical formulations and the validity of the numerical methods and programs used. All mechanical tests were conducted in accordance to ISO, ASTM, GOST standards.

During the study five following journal articles were published:

• Thermoplastic pultrusion: A review / K. Minchenkov, A. Vedernikov, A. Safonov, I. Akhatov // Polymers. - 2021. - Vol. 13. - № 2. - P. 1-36. https://doi.org/10.3390/polym13020180.

• Pultrusion of thermoplastic composites with mechanical properties comparable to industrial thermoset profiles / K. Minchenkov, S. Gusev, A. Rogozheva [et al.] // Composites Communications. - 2023. - Vol. 44. - № October. - P. 101766. https://doi.org/10.1016/j.coco.2023.101766.

• Effects of the quality of pre-consolidated materials on the mechanical properties and morphology of thermoplastic pultruded flat laminates / K. Minchenkov, A. Vedernikov, Y. Kuzminova [et al.] // Composites Communications. - 2022. -Vol. 35. - № February. - P. 101281. https://doi.org/10.1016/j.coco.2022.101281.

• Effects of the Pre-Consolidated Materials Manufacturing Method on the Mechanical Properties of Pultruded Thermoplastic Composites / A. Vedernikov,

K. Minchenkov, S. Gusev [et al.] // Polymers. - 2022. - Vol. 14. - № 11. https://doi.org/10.3390/polym14112246.

• Experimental and numerical analyses of the thermoplastic pultrusion of large structural profiles / K. Minchenkov, S. Gusev, A. Sulimov [et al.] // Materials & Design. - 2023. - Vol. 232. - № February. - P. 112149. https://doi.org/10.1016/i.matdes.2023.112149.

Two following scientific reports were presented at the conferences:

• Prediction of temperature regimes in pultrusion of thermoplastic laminates / K. Minchenkov, A. Safonov, S. Gusev [et al.] // 25th International Conference on Composite Structures. - Portugal, 2022. - P. 181.

• Thermoplastic pultrusion of rods with various reinforcement content / K. Minchenkov, S. Gusev, Y. Yavorsky [et al.] // International conference of young scientists and student's topical problems of mechanical engineering. - Moscow, 2023. - P. 59-66.

The results of the thesis were obtained by the applicant through a series of personal and direct contributions. The applicant conducted a comprehensive literature search and analysis related to the research topic, performed mechanical tests, prepared samples, and performed microscopy. The mathematical model of heat transfer was developed by the applicant under the supervision of Associate Professor A. Safonov. The production of tapes and pultrusion composite material was conducted by the applicant under the guidance of Senior Engineer S. Gusev in the Laboratory of Composite Materials and Structures at the Skolkovo Institute of Science and Technology. The fabrication of materials for the window structure was conducted by the research group of the Materials Technology Center of the Skolkovo Institute of Science and Technology. The analysis of the obtained data regarding the window structure was carried out by the applicant as a chapter part of this thesis.

The dissertation structure consists of an abstract, six chapters, conclusions, list of figures, list of tables, list of abbreviations, bibliography of 174 references and

acknowledgements. The full volume of the dissertation is 123 pages, including 58 figures and 18 tables.

Chapter 1 is introduction. Chapter 2 is devoted to the literature review. The main parameters of thermoplastic pultrusion, prepregs used and modeling are analyzed. Chapter 2 was written based on published author's work [168]. Chapter 3 presents a description of the materials used for the current study and describes the methods used to manufacture materials and investigate their properties. The Chapter 4 concerns the influence of prepreg types and its quality on the mechanical properties of manufactured strip profiles. Some profiles were pultruded at different pulling speed to assess their effect on mechanical properties of profiles. The results presented in Chapter 4 were published by the author in [169,170,171, 174]. Chapter 5 presents a model for heat transfer analysis in the pultrusion process. The model was validated using experimental data. The model enabled the analysis of temperature distribution within the profile as a function of pulling speed. Chapter 5 was written based on author's published work [172,173]. In Chapter 6, the optimal heating temperatures and pulling speeds for the fabrication of channel and tube were selected using the developed heat transfer model. The tube and channel were applied as a reinforcing core in a window structure to improve thermal resistance of the window. Flowchart of the study is shown in Figure 1.1.

Список литературы диссертационного исследования кандидат наук Минченков Кирилл Олегович, 2024 год

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Author's publications on the dissertation topic

168. Thermoplastic pultrusion: A review / K. Minchenkov, A. Vedernikov, A. Safonov, I. Akhatov // Polymers. - 2021. - Vol. 13. - № 2. - P. 1-36.

169. Pultrusion of thermoplastic composites with mechanical properties comparable to industrial thermoset profiles / K. Minchenkov, S. Gusev, A. Rogozheva [et al.] // Composites Communications. - 2023. - Vol. 44. - № October. - P. 101766.

170. Effects of the quality of pre-consolidated materials on the mechanical properties and morphology of thermoplastic pultruded flat laminates / K. Minchenkov, A. Vedernikov, Y. Kuzminova [et al.] // Composites Communications. - 2022. - Vol. 35. - № February. - P. 101281.

171. Effects of the Pre-Consolidated Materials Manufacturing Method on the Mechanical Properties of Pultruded Thermoplastic Composites / A. Vedernikov, K. Minchenkov, S. Gusev [et al.] // Polymers. - 2022. - Vol. 14. - № 11.

172. Experimental and numerical analyses of the thermoplastic pultrusion of large structural profiles / K. Minchenkov, S. Gusev, A. Sulimov [et al.] // Materials &

Design. - 2023. - Vol. 232. - № February. - P. 112149.

173. Prediction of temperature regimes in pultrusion of thermoplastic laminates / K. Minchenkov, A. Safonov, S. Gusev [et al.] // 25th International Conference on Composite Structures. - Portugal, 2022. - P. 181.

174. Thermoplastic pultrusion of rods with various reinforcement content / K. Minchenkov, S. Gusev, Y. Yavorsky [et al.] // International conference of young scientists and student's topical problems of mechanical engineering. - Moscow, 2023. - P. 59-66.