Innovative unidirectional recycled carbon fiber tape structure for high performance thermoplastic composites: technological developments, technology-structure-property relationship and modeling of composite tensile properties

Muhammad Furqan Khurshid

AutorIn

Muhammad Furqan Khurshid

Titel

Innovative unidirectional recycled carbon fiber tape structure for high performance thermoplastic composites: technological developments, technology-structure-property relationship and modeling of composite tensile properties

Zitierfähige Url:

https://nbn-resolving.org/urn:nbn:de:bsz:14-qucosa2-838495

Übersetzter Titel (DE)

Innovative unidirektionale rCF-Tapestruktur für hochleistungsfähige thermoplastische Verbundwerkstoffe: technologische Entwicklungen, Technologie-Struktur-Eigenschafts-Beziehung und Modellierung der Zugeigenschaften von Verbundwerkstoffen

Erstveröffentlichung

2023

Datum der Einreichung

16.08.2022

Datum der Verteidigung

09.12.2022

Abstract (EN)

The rapidly growing demand for carbon fiber reinforced plastics in high-tech industries, such as aerospace, defense, automotive, wind turbine engineering, building and sports, resulted in a high amount of waste in the form of dry waste (e.g., production off-cuts), wet waste (e.g., out-of-date prepreg) and end-of-life components waste (e.g., aircraft components). Furthermore, the production of carbon fibers is cost and energy-intensive. Therefore, technological developments for the gentle processing of recycled carbon fiber and its integration into high-performance composites with promising tensile properties have gained considerable attention. Consequently, injection molding, nonwovens and hybrid yarn technologies were developed in recent years to integrate recycled carbon fiber into the high-performance thermoplastic composite. It is unfortunate that these technologies develop composites with a lack of unidirectional fiber orientation; therefore, the potential of recycled carbon fiber in high-performance composites is not thoroughly exhausted. This thesis primarily addresses the development of an innovative structure with a unidirectional fiber orientation termed “unidirectional recycled carbon fiber tape structure” for high-performance thermoplastics composites. The technological concept of the unidirectional structure comprises fiber opening, carding, drawing and a novel tape-forming process. In this concept, fiber opening, carding, and drawing processes were utilized to develop homogeneous, uniform, and highly oriented hybrid slivers. In the next step, these hybrid slivers were converted into a unidirectional recycled carbon fiber tape structure through a novel tape-forming process. To implement this concept, technological developments (investigations, modifications, optimization and further developments), were carried out in fiber opening, carding and drawing processes to develop a hybrid sliver with improved uniformity, homogeneity and unidirectional orientation. In the second phase, conception, design, technological developments, construction and prototype development were implemented to develop a novel tape-forming process. The result confirms that tape development technology comprising fiber opening, carding, drawing and prototype tape forming processes is an innovative, eco-friendly and sustainable technology compared to existing technologies. Furthermore, the consolidation process transformed the unidirectional tape structure into high-performance thermoplastic composites. Subsequently, technology-structure-property relationships were established to develop composites with tailor-made properties. The analysis reveals that selecting optimum technological, consolidation and structural parameters develop tape and composite structures with unidirectional fiber orientation. As a result, experimental results of a high-performance composite developed from a unidirectional recycled carbon fiber tape structure show a very high tensile strength of 1350 ± 28 MPa and an E-module of 84.7 ± 2.3 GPa. This analysis confirms that unidirectional fibers configuration in composites brings a revolution toward developing cost-efficient, high-performance composites for load-bearing structural applications. Finally, theoretical and finite element modeling of tensile properties of high-performance composites reveals that modified models show good agreement with composite tensile properties.

Verweis

Uni-directional tape structures consisting of recycled carbon fibres and polyamide 6 fibers for high-performance thermoplastic composites
DOI: 10.4028/p-4nx4ct

Processing of waste carbon and polyamide fibers for high performance thermoplastic composites: A novel manufacturing technology for unidirectional tapes structure
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Processing of waste carbon and polyamide fibers for high-performance thermoplastic composites: Modifications to the auto-leveling system to enhance the quality of hybrid drawn sliver
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Processing of waste carbon and polyamide fibres for high performance thermoplastic composites: Influence of carding parameters on fibre orientation, fibre length and sliver cohesion force
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Recent developments in the processing of waste carbon fibre for thermoplastic composites - A review
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Process development for uni directional tape structure based on recycled carbon fiber and thermoplastic fibers for fiber reinforced plastics
Link: https://ojs.ugent.be/autex/article/view/11656

Freie Schlagwörter (EN)