1. Processing of Thermoplastic Composite Structures Gabriel Gumede Department of Mechanical Engineering Durban University of Technology November 2007

2. Slide 2 © CSIR 2006 www.csir.co.za Introduction What is Thermoplastic composite Thermoplastic:Deformable, melts to liquid and freezes to brittle glass state. Recyclable (remelted and remoulded). Composite:Material made from two or more materials with different physical or chemical properties and remain separate and distinct within the finished structure. Thermoplastic composite is a recyclable, reinforced plastic material. Polymeric composite application Automotive, aerospace, marine, civil construction, sports, and many others.

3. Slide 3 © CSIR 2006 www.csir.co.za Problem Statement

4. Slide 4 © CSIR 2006 www.csir.co.za Nanocomposites Vacuum Bagging

5. Slide 5 © CSIR 2006 www.csir.co.za Autoclaving Enhances composite bonding and curing. Resin Transfer Moulding

6. Slide 6 © CSIR 2006 www.csir.co.za Thermoforming

7. Slide 7 © CSIR 2006 www.csir.co.za Work already done Kunihiko Murayama - orietation control of short fibres in a - liquid matrix by loading a magnetic field. - Nickel coated graphite fibre - ultrasonic vibration Liu and Chen developed water- assisted injection moulding technology. Water penetrates into the core of the composite and pushes the material into the mould wall thereby aligning the fibres in the mould direction.

8. Slide 8 © CSIR 2006 www.csir.co.za Manufacturing Processes Pultrusion Extrusion moulding Compression moulding Injection moulding

9. Slide 9 © CSIR 2006 www.csir.co.za Pultrusion Process

10. Slide 10 © CSIR 2006 www.csir.co.za Modified Pultrusion/Extrusion Moulding Process creel Fibre spreader Heater rollers Impregnating tool With rollers chiller Pullers Winder

11. Slide 11 © CSIR 2006 www.csir.co.za Impregnating Tool Rollers Tool mouth Fibre entrance port

12. Slide 12 © CSIR 2006 www.csir.co.za Extrusion moulding

13. Slide 13 © CSIR 2006 www.csir.co.za Principle of a Plasticator

14. Slide 14 © CSIR 2006 www.csir.co.za Compression moulding

15. Slide 15 © CSIR 2006 www.csir.co.za Injection moulding

16. Slide 16 © CSIR 2006 www.csir.co.za Thermoplastic Pellets (TP) Glass fibres Process Chart Modified PultrusionTP with glass fibres Heating Extrusion Hot pressing Components Injection moulding

17. Slide 17 © CSIR 2006 www.csir.co.za Fibre Orientation Factors affecting fibre orientation Moulding processes Gates, Initial Charge and Part Geometry Thickness of the moulded part

18. Slide 18 © CSIR 2006 www.csir.co.za Outline of Research Develop a technique of aligning glass fibres using extrusion, injection and compression moulding processes. Optimise the mechanical properties by controlling the fibre orientation. Determine critical fibre length Produce complex shaped reinforced thermoplastic composite components. Test and analyse reinforced thermoplastic components.

19. Slide 19 © CSIR 2006 www.csir.co.za I would like to thank Kenton for their support through the Hystou programme