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Institute for Carbon Composites donated by
Morphology Development and MechanicalProperties of Interfaces between EpoxyResin and Thermoplastic Films
Philipp Bruckbauer
„A Comprehensive Approach to Carbon Composites Technology“Symposium on the Occasion of the 5 th Anniversary of the Institute for Carbon Composites
Research Campus Garching, September 11th - 12th 2014
2
Conclusion5
Mechanical Performance4
Morphology Development and Process Window3
Approach for Interface Analysis2
Introduction1
Agenda
12/09/2014 | P. Bruckbauer | Interfaces between Epoxy Resin and Thermoplastic Films
3
Conclusion5
Mechanical Performance4
Morphology Development and Process Window3
Approach for Interface Analysis2
Introduction1
Agenda
12/09/2014 | P. Bruckbauer | Interfaces between Epoxy Resin and Thermoplastic Films
4
Thermoplastic Functional Layers
12/09/2014 | P. Bruckbauer | Interfaces between Epoxy Resin and Thermoplastic Films
Film
CF/epoxy part
Thermoplasticclip
Joining surfaceHigh class surfaceMoisture and corrosion barrier
Integrated circuits
Interface
Reinforcement fibers
Thermoset matrix
Thermoplastic film
5
Production Process
12/09/2014 | P. Bruckbauer | Interfaces between Epoxy Resin and Thermoplastic Films
Preforming PartInjection
Functional film
Preform
Functional film
Tool
CFRP part
Part with functional surface layer
6
Material Systems and Interface Structure
12/09/2014 | P. Bruckbauer | Interfaces between Epoxy Resin and Thermoplastic Films
� Graded material interface� Original Material
Epoxy resin
Amorphousthermoplast
[1] G.W. Ehrenstein, Polymerwerkstoffe: Struktur – Eigenschaften – Anwendung, Carl Hanser Verlag, München, 2011
[1]
[1]
7
Conclusion5
Mechanical Performance4
Morphology Development and Process Window3
Approach for Interface Analysis2
Introduction1
Agenda
12/09/2014 | P. Bruckbauer | Interfaces between Epoxy Resin and Thermoplastic Films
8
Approach for Interface Analysis
12/09/2014 | P. Bruckbauer | Interfaces between Epoxy Resin and Thermoplastic Films
Hot stage experiments Resin kinetic model Mechanical tests
• Degree of cure• Degree of cure at phase separation• Time for interphase formation
• Solubility in resin system• Solubility temperature• Time of phase separation
Process cycle and interdependence of material structure and performance
• GIc• GIIc• Fracture surface
9
Conclusion5
Mechanical Performance4
Morphology Development and Process Window3
Approach for Interface Analysis2
Introduction1
Agenda
12/09/2014 | P. Bruckbauer | Interfaces between Epoxy Resin and Thermoplastic Films
10
Solution Process
12/09/2014 | P. Bruckbauer | Interfaces between Epoxy Resin and Thermoplastic Films
PEI in RTM6
1112/09/2014 | P. Bruckbauer | Interfaces between Epoxy Resin and Thermoplastic Films
PEI in RTM6 at 40°C Solution onset at 120°C Solution process at 130°C
Solution ProcessSolution and Phase Separation of PEI in RTM6
Solution process at 140°C
Solution process at 150°C Phase separation Interface formation Final interface
12
Interface Morphology
12/09/2014 | P. Bruckbauer | Interfaces between Epoxy Resin and Thermoplastic Films
of RTM6 - PPSU Interface
Epoxy resin 90% epoxy resin with 10% thermoplast
80% epoxy resin with 20% thermoplast
50% epoxy resin with 50% thermoplast
Transition of interface to neat thermoplast
a b c d e
a b c d e
Continuous thermoplastphase with epoxy domains
ThermoplastContinuous epoxy phase with thermoplast domainsEpoxy resin
13
0
50
100
150
200
250
0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
1
0 2000 4000 6000 8000 10000 12000 14000
Tem
pe
ratu
re [°C
]
De
gre
e o
f cu
re,
solu
tio
n r
ate
Time[s]
Process Window
12/09/2014 | P. Bruckbauer | Interfaces between Epoxy Resin and Thermoplastic Films
RTM6 - PEI
TS Solution temperature α� Degree of cure at phase separation α��� Degree of cure at gelpoint
Solution rateDegree of cure Temperature
α� α���T�
2 Phases Solution 2 Phases
14
Conclusion5
Mechanical Performance4
Morphology Development and Process Window3
Approach for Interface Analysis2
Introduction1
Agenda
12/09/2014 | P. Bruckbauer | Interfaces between Epoxy Resin and Thermoplastic Films
15
Approach for Perfomance Analysis
12/09/2014 | P. Bruckbauer | Interfaces between Epoxy Resin and Thermoplastic Films
Analysis of fracture surfaceInterlaminar energy release rate in mode I and mode II
� Adhesion of film� Identify weak points
� Mode of failure� Interface shape
DCB sprecimen
Loading blocks
Initial crack
F
F
TP film
F
Initial crack Specimen
Compression fin
Bearing
TP film
16
Interlaminar Energy Release Rate in Mode I (GIc)
12/09/2014 | P. Bruckbauer | Interfaces between Epoxy Resin and Thermoplastic Films
According to DIN EN 6033
0,00 200,00 400,00 600,00 800,00 1000,00 1200,00 1400,00
CF/EP/PEI
CF/EP/PES
CF/EP/PPSU
CF/EP/PSU
Ref CF/EP
GIc [J/m²]
+96%
+195%
+121%
+147%
DCB sprecimen
Loading blocks
Initial crack
F
F
TP film
CF: Carbon fiber EP: Epoxy resin
17
Interlaminar Energy Release Rate in Mode II (GIIc)
12/09/2014 | P. Bruckbauer | Interfaces between Epoxy Resin and Thermoplastic Films
According to DIN EN 6034
0 200 400 600 800 1000 1200 1400 1600 1800 2000
CF/EP/PEI
CF/EP/PES
CF/EP/PPSU
CF/EP/PSU
Ref CF/EP
GIIc [J/m²]
+111%
+7%
+48%
+47%
F
Initial crack Specimen
Compression fin
Bearing
CF: Carbon fiber EP: Epoxy resin
18
� CF/EP/PEI
Analysis of Fracture Surfaces (GIc test)
12/09/2014 | P. Bruckbauer | Interfaces between Epoxy Resin and Thermoplastic Films
� CF/EP/PPSU
� CF/EP/PES
� Ref CF/EP � CF/EP/PSU
Matrix failure Fiber pull out, clean fiber surfaces Fiber pull out, clean fiber surfaces
Matrix failure, clean fiber surfaces Ripped out fiber bundles and matrix failure
19
Conclusion5
Mechanical Performance4
Morphology Development and Process Window3
Approach for Interface Analysis2
Introduction1
Agenda
12/09/2014 | P. Bruckbauer | Interfaces between Epoxy Resin and Thermoplastic Films
20
� Possibility for expanded material usage� Addition of functionality to state of the art
resin systems� Combination of epoxy resin and
amorphous thermoplastics with high Tgresult in a gradient interface
� Excellent mechanical performance
� Acknowledgment:The presented work was carried out in the framework of BMBF funded projects.
12/09/2014 | P. Bruckbauer | Interfaces between Epoxy Resin and Thermoplastic Films
Conclusion
CFRP part with PEI surface
21
Technische Universität MünchenInstitute for Carbon CompositesBoltzmannstraße 1585748 Garchingwww.lcc.mw.tum.de
Contact
Address
FaxEmail
TelRoom
+49 89 /+49 89 /
Institute for Carbon Composites donated by
Dipl.-Ing. Philipp Bruckbauer
289 - 103858102.03.105
289 - [email protected]