碳纤维/尼龙6预浸料的制备及盒体的热冲压成型工艺
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摘要
首先利用自主设计的熔融浸渍机头制备了60mm幅宽的连续碳纤维增强尼龙6(CF/PA6)热塑单向带,并利用快速热冲压成型技术制备了CF/PA6复合材料矩形盒体。结果显示,在CF/PA6预浸料制备过程中,纤维展纱包覆角与纤维展宽呈线性关系;预紧力增加展纱宽度的同时,牵引力会呈指数急剧上升,因此应避免大的预紧力;CF/PA6预浸料的浸渍质量随牵引速度的增加而降低;预热有利于改善高浸渍速度下的浸渍质量。在热冲压成型过程中,CF/PA6复合材料的最佳预热温度为260～280℃,模具温度为130～160℃,并应经过预压实。
The continuous carbon fiber reinforced polyamide 6(CF/PA6)unidirectional prepreg of 60 mm width was prepared by a molten impregnation method.A structure of CF/PA6 composites rectangular box was then manufactured by hot stamping method.The results show that the fiber spread width shows a linear relationship with the wrap angle.The large pretension force should be avoided due to the high pulling force which will be accumulated and result in the fiber's breaking up.The high pulling speed results in pool impregnation quality.The pre-heating of CF can improve the pool impregnation quality under high pulling speed.In hot stamping,the pre-consolidation is necessary and the desirable preheating temperature and forming temperature are in the range of 260-280℃ and 130-160℃,respectively.
The continuous carbon fiber reinforced polyamide 6(CF/PA6)unidirectional prepreg of 60 mm width was prepared by a molten impregnation method.A structure of CF/PA6 composites rectangular box was then manufactured by hot stamping method.The results show that the fiber spread width shows a linear relationship with the wrap angle.The large pretension force should be avoided due to the high pulling force which will be accumulated and result in the fiber's breaking up.The high pulling speed results in pool impregnation quality.The pre-heating of CF can improve the pool impregnation quality under high pulling speed.In hot stamping,the pre-consolidation is necessary and the desirable preheating temperature and forming temperature are in the range of 260-280℃ and 130-160℃,respectively.
引文
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[16]方立.连续纤维增强热塑性复合材料制备及其性能的研究[D].上海:华东理工大学,2012.FANG L.Study on preparation and characters of continuous fiber reinforced thermoplastic composites[D].Shanghai:East China University of Science and Technology,2012(in Chinese).
[17] ALAGIRUSAMY R,OGALE V.Development and characterization of GF/PET,GF/nylon,and GF/PP commingled yarns for thermoplastic composites[J].Journal of Thermoplastic Composite Materials,2005,18(3):269-285.
[18]张志法,刘颖,徐永军,等.一种由玻璃纤维和聚丙烯纤维组成的复合纤维的制造方法:中国,01127551.0[P].2001-10-16.ZHANG Z F,LIU Y,XU Y J,et al.A method for commingled fibers preparation consisted of glass fibers and PP fibers:China,01127551.0[P].2001-10-16(in Chinese).
[19]吴学东,丁辛.热塑性树脂基复合材料用摩擦纺混纤纱[J].玻璃钢/复合材料,1997(4):5-7.WU X D,DING X.Friction spun hybrid yarns used for thermoplastic resin matrix composites[J].Fiber Reinforced Plastics/Composites,1997(4):5-7(in Chinese).
[20] ZINGRAFF L,MICHAUD V,BOURBAN P E,et al.Resin transfer moulding of anionically polymerised polyamide 12[J].Composites Part A:Applied Science and Manufacturing,2005,36(12):1675-1686.
[21]卢红,史德军,靳楠,等.原位聚合玻纤-尼龙6热塑性复合材料的研究[J].功能高分子学报,2005,18(3):405-408.LU H,SHI D J,JIN N,et al.Study on continue glass fiber reinforced nylon 6thermoplastic composites by in-situ polymerization[J].Journal of Functional Polymers,2005,18(3):405-408(in Chinese).
[22] BAETS J,DEVAUX J, VERPOEST I.Toughening of basalt fiber-reinforced composites with a cyclic butylene terephthalate matrix by a nonisothermal production method[J].Advances in Polymer Technology,2010,29(2):70-79.
[23] YAN C,LI H,ZHANG X,et al.Preparation and properties of continuous glass fiber reinforced anionic polyamide-6thermoplastic composites[J].Materials&Design,2013,46:688-695.
[24]孙银宝,李宏福,张博明.连续纤维增强热塑性复合材料研发与应用进展[J].航空科学技术,2016,27(5):1-7.SUN Y B,LI H F,ZHANG B M.Progress in research and application of continuous fiber reinforced thermoplastic composites[J].Aeronautical Science&Technology,2016,27(5):1-7(in Chinese).
[25] WAKEMAN M D,CAIN T A,RUDD C D,et al.Compression moulding of glass and polypropylene composites for optimised macro and micro-mechanical properties-1commingled glass and polypropylene[J].Composites Science and Technology,1998,58(12):1879-1898.
[26] YE L,CHEN Z R,LU M,et al.De-consolidation and reconsolidation in CF/PPS thermoplastic matrix composites[J].Composites Part A:Applied Science and Manufacturing,2005,36(7):915-922.
[27] TRUDEL-BOUCHER D,FISA B,DENAULT J,et al.Experimental investigation of stamp forming of unconsolidated commingled E-glass/polypropylene fabrics[J].Composites Science and Technology,2006,66(3-4):555-570.
[28] GORCZYCA-COLE J L,SHERWOOD J A,CHEN J.A friction model for thermostamping commingled glass-polypropylene woven fabrics[J].Composites Part A:Applied Science and Manufacturing,2007,38(2):393-406.
[29]张衡,严飙,龚友坤,等.碳纤维机织物增强热塑性树脂复合材料热冲压叠层模型[J].复合材料学报,2017,34(12):2741-2746.ZHANG H,YAN B,GONG Y K,et al.A lamination model for thermostamping of carbon woven fabric reinforced thermoplastic resin composites[J].Acta Materiae Compositae Sinica,2017,34(12):2741-2746(in Chinese).
[2] LI H F,WANG Y,ZHANG C W,et al.Effects of thermal histories on interfacial properties of carbon fiber/polyamide 6composites:Thickness, modulus, adhesion and shear strength[J].Composites Part A:Applied Science and Manufacturing,2016,85:31-39.
[3] WEUSTINK A P D.Development of a rapid thermoplastic impregnation device[D].Delft:Delft University of Technology,2008.
[4] NYGARD P,GUSTAFSON C G.Continuous glass fiberpolypropylene composites made by melt impregnation:Influence of processing method[J].Journal of Thermoplastic Composite Materials,2004,17(2):167-184.
[5] PELTONEN P,LAHTEENKORVA K,PAAKKONEN E J,et al.The influence of melt impregnation parameters on the degree of impregnation of a polypropylene/glass fibre prepreg[J].Journal of Thermoplastic Composite Materials,1992,5(4):318-343.
[6] GAYMANS R J,WEVERS E.Impregnation of a glass fibre roving with a polypropylene melt in a pin assisted process[J].Composites Part A:Applied Science and Manufacturing,1998,29(5):663-670.
[7] GOODMAN K E,LOOS A C.Thermoplastic prepreg manufacture[J].Journal of Thermoplastic Composite Materials,1990,3(1):34-40.
[8]王荣国,刘文博,张东兴,等.连续玻璃纤维增强热塑性复合材料工艺及力学性能的研究[J].航空材料学报,2001,21(2):44-47.WANG R G,LIU W B,ZHANG D X,et al.Study on mechanical properties and processing parameters of continuous fiber reinforced thermoplastic composites[J].Journal of Aeronautical Materials,2001,21(2):44-47(in Chinese).
[9]孙明,陈平,刘扬,等.连续纤维增强聚芳醚砜酮复合材料的性能[J].纤维复合材料,2004,21(1):3-6.SUN M,CHEN P,LIU Y,et al.Properties of continuous fiber reinforced PPESK composites[J].Fiber Composites,2004,21(1):3-6(in Chinese).
[10] DEBENEDICTIS M A.Glass fiber/polypropylene prepregs produced by electrostatic fluidized bed powder fusion coating[D].Atlanta:Georgia Institute of Technology,1991.
[11]周晓东,周成玉,张胜勇,等.连续玻璃纤维增强聚丙烯预浸料粉末法浸渍过程及界面控制[J].玻璃钢/复合材料,2000(2):5-8.ZHOU X D,ZHOU C Y,ZHANG S Y,et al.Powder impregnation process and interface control of continuous glass fiber reinforced polypropylene[J].Fiber Reinforced Plastics/Composites,2000(2):5-8(in Chinese).
[12]季涛,潘虹,黄晓梅,等.流化床工艺制备连续纤维增强热塑性复合材料纤维含量的控制[J].南通大学学报(自然科学版),2008,7(4):41-44.JI T,PAN H,HUANG X M,et al.Control of fiber content in continuous fiber reinforced thermoplastic plastic composites produced with fluidized bed technology[J].Journal of Nantong University(Natural Science Edition),2008,7(4):41-44(in Chinese).
[13] CLAIRE S,PAVEL S,SURESH A,et al.A model for thermoplastic melt impregnation of fiber bundles during consolidation of powder-impregnated continuous fiber composites[J].Composites Part A:Applied Science and Manufacturing,2010,41(1):93-100.
[14]章奕定,李卫中.PPS泥浆法预浸技术的研究[J].玻璃钢/复合材料,1997(2):35-36.ZHANG Y D,LI W Z.Slurry method for PPS prepreg preparation[J].Fiber Reinforced Plastics/Composites,1997(2):35-36(in Chinese).
[15]邢玉清,王军,孟令辉.中长纤维毡/高分子量PPS悬浮液含浸法热塑性复合材料工艺研究[J].复合材料学报,1995,12(4):44-48.XING Y Q,WANG J,MENG L H.Technology properties of middle length fiber-felt/high molecular weight PPS suspension thermoplastic composites using impregnation method[J].Acta Materiae Compositae Sinica,1995,12(4):44-48(in Chinese).
[16]方立.连续纤维增强热塑性复合材料制备及其性能的研究[D].上海:华东理工大学,2012.FANG L.Study on preparation and characters of continuous fiber reinforced thermoplastic composites[D].Shanghai:East China University of Science and Technology,2012(in Chinese).
[17] ALAGIRUSAMY R,OGALE V.Development and characterization of GF/PET,GF/nylon,and GF/PP commingled yarns for thermoplastic composites[J].Journal of Thermoplastic Composite Materials,2005,18(3):269-285.
[18]张志法,刘颖,徐永军,等.一种由玻璃纤维和聚丙烯纤维组成的复合纤维的制造方法:中国,01127551.0[P].2001-10-16.ZHANG Z F,LIU Y,XU Y J,et al.A method for commingled fibers preparation consisted of glass fibers and PP fibers:China,01127551.0[P].2001-10-16(in Chinese).
[19]吴学东,丁辛.热塑性树脂基复合材料用摩擦纺混纤纱[J].玻璃钢/复合材料,1997(4):5-7.WU X D,DING X.Friction spun hybrid yarns used for thermoplastic resin matrix composites[J].Fiber Reinforced Plastics/Composites,1997(4):5-7(in Chinese).
[20] ZINGRAFF L,MICHAUD V,BOURBAN P E,et al.Resin transfer moulding of anionically polymerised polyamide 12[J].Composites Part A:Applied Science and Manufacturing,2005,36(12):1675-1686.
[21]卢红,史德军,靳楠,等.原位聚合玻纤-尼龙6热塑性复合材料的研究[J].功能高分子学报,2005,18(3):405-408.LU H,SHI D J,JIN N,et al.Study on continue glass fiber reinforced nylon 6thermoplastic composites by in-situ polymerization[J].Journal of Functional Polymers,2005,18(3):405-408(in Chinese).
[22] BAETS J,DEVAUX J, VERPOEST I.Toughening of basalt fiber-reinforced composites with a cyclic butylene terephthalate matrix by a nonisothermal production method[J].Advances in Polymer Technology,2010,29(2):70-79.
[23] YAN C,LI H,ZHANG X,et al.Preparation and properties of continuous glass fiber reinforced anionic polyamide-6thermoplastic composites[J].Materials&Design,2013,46:688-695.
[24]孙银宝,李宏福,张博明.连续纤维增强热塑性复合材料研发与应用进展[J].航空科学技术,2016,27(5):1-7.SUN Y B,LI H F,ZHANG B M.Progress in research and application of continuous fiber reinforced thermoplastic composites[J].Aeronautical Science&Technology,2016,27(5):1-7(in Chinese).
[25] WAKEMAN M D,CAIN T A,RUDD C D,et al.Compression moulding of glass and polypropylene composites for optimised macro and micro-mechanical properties-1commingled glass and polypropylene[J].Composites Science and Technology,1998,58(12):1879-1898.
[26] YE L,CHEN Z R,LU M,et al.De-consolidation and reconsolidation in CF/PPS thermoplastic matrix composites[J].Composites Part A:Applied Science and Manufacturing,2005,36(7):915-922.
[27] TRUDEL-BOUCHER D,FISA B,DENAULT J,et al.Experimental investigation of stamp forming of unconsolidated commingled E-glass/polypropylene fabrics[J].Composites Science and Technology,2006,66(3-4):555-570.
[28] GORCZYCA-COLE J L,SHERWOOD J A,CHEN J.A friction model for thermostamping commingled glass-polypropylene woven fabrics[J].Composites Part A:Applied Science and Manufacturing,2007,38(2):393-406.
[29]张衡,严飙,龚友坤,等.碳纤维机织物增强热塑性树脂复合材料热冲压叠层模型[J].复合材料学报,2017,34(12):2741-2746.ZHANG H,YAN B,GONG Y K,et al.A lamination model for thermostamping of carbon woven fabric reinforced thermoplastic resin composites[J].Acta Materiae Compositae Sinica,2017,34(12):2741-2746(in Chinese).