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Material Properties of Injection Molded Glass and
Carbon Fiber Reinforced Thermoplastic Composites –
A Review
SPE Automotive Composites Conference & Exhibition, Sept. 7-9 2016
Mark Cieslinski, BASF - Advanced Materials & Systems Research
© 2016 BASF Corporation
About BASF1
Why Composites?2
What Influences Composite Properties?3
Summary4
5
Outline
2© 2016 BASF Corporation
About BASF1
Why Composites?2
What Influences Composite Properties?3
Summary4
5
Outline
3© 2016 BASF Corporation
BASF – We create chemistry
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Our chemistry is used in almost all
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We combine economic success, social
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protection
Sales 2015: €70,449 million
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112,435
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production sites
© 2016 BASF Corporation
Expenditures for research and development
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been on the market since 2011
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we provide sustainable solutions for global challenges.
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5
© 2016 BASF Corporation
Advanced Materials & Systems:
Global research Verbund
6
Ludwigshafen Lemfoerde
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Muenster
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BaselDuesseldorf
© 2016 BASF Corporation
About BASF1
Why Composites?2
What Influences Composite Properties?3
Summary4
5
Outline
7© 2016 BASF Corporation
Metal replacement: comparison with
engineering plastics compounds
Low density even for highly glass fiber filled PA compound is advantageous
Tensile strength of PA compound is high and comparable to “soft“ Al alloys
Stiffness and fracture toughness as well as melting point and thermal conductivity
much lower compared to metals
Material rg/cm³
Tm
°C
E
GPa
s
MPa
KIC
MN/m³/²
l
W/mK
Steel (ferritic, austenitic)
7.8 1150(FeC4)
195 - 210 440 - 750 50 - 200 30 - 60
Steel(High-strength )
7.8 - 195 - 210 1300 - 2100 - -
Al alloys 2.7 577(AlSi12)
60 - 80 300 - 700 23 - 45 121 - 237
PA66 GF50(23 °C, dry conditions)
1.56 260 16.8 240 5 - 10 (~ 0.5)
Steel and Al-alloys: Data taken from Hütte (1996)
8© 2016 BASF Corporation
Specific tensile strength & stiffness
of PA66 compounds
Specific tensile
strength of highly
GF-filled PA com-
pounds similar to
Al-alloys and higher
than steel
Specific stiffness of
PA/GF compounds
further enhanced by
carbon fibers
Al-alloys
Steel
High-strength steel
Comparison of glass & carbon fibers
9© 2016 BASF Corporation
About BASF1
Why Composites?2
What Influences Composite Properties?3
Summary4
5
Outline
10© 2016 BASF Corporation
Question:
What injection molding material do we use for
our application?
How do these variables transfer to
mechanical properties?
Modulus
Strength
Impact
Fatigue
Short or Long fiber?
Glass or Carbon fiber?
Resin?
© 2016 BASF Corporation 11
Designations of Fiber Lengths
Short fibers – incorporated into thermoplastic via extrusion compounding,
typical average fiber length < 0.5 mm
Long fibers – composites retain fiber length in molded part > 1.0 mm,
pultrusion or wet-lay processes are used
Extrusion/Injection molding reduces fiber length to a log-normal distribution,
described by:
Number average fiber length, Ln = 𝑁𝑖𝐿𝑖 𝑁𝑖
Weight average fiber length, Lw = 𝑁𝑖𝐿𝑖
2
𝑁𝑖𝐿𝑖
Aspect Ratio = Length
Diameter
© 2016 BASF Corporation 12
Num
ber
of
Fib
ers
, 𝑁𝑖
Fiber Length, 𝐿𝑖
Fiber length
distribution
0
0.2
0.4
0.6
0.8
1
1.2
0.01 0.1 1 10 100
No
rmal
ized
Pro
per
ty
Fiber Length, mm
Modulus
Strength
Notched CharpyImpact
Fiber Length Trends
Modulus – Cox model
Strength – Kelly-Tyson Model
Impact – Thomason-Vlug model
Modulus
Strength
Impact
10-40 wt% glass – Polypropylene
produced via wet-lay process
Normalization trend appears independent of
concentration for Flexural and Tensile data
J. Thomason and M. Vlug, "Influence of fibre length and concentration on the properties of glass fibre-reinforced polypropylene: 4. Impact properties,"
Composites: Part A, pp. 277-288, 1997.
J. Thomason, "The influence of fibre length and concentration on the properties of glass fibre reinforced polypropylene: 5. Injection moulded long and short fiber
PP," Composites: Part A, pp. 1641-1652, 2002.© 2016 BASF Corporation 13
Injection Molded Composites
Long Glass Fiber - Polypropylene
Number Average, Ln
Length Average, Lw
J. Thomason, "The influence of fibre length and concentration on the properties of glass fibre reinforced polypropylene. 6. The properties of injection moulded
long fibre PP at high fibre content," Composites: Part A, pp. 995-1003, 2005.
Fiber length decreases with
increasing concentration
© 2016 BASF Corporation 14
Modulus linearly increasing with
concentration (except >65wt%)
Ultramid® Polyamide Glass Fiber Materials
0
5
10
15
20
25
PA
66
15
% S
ho
rt G
lass
25
% S
ho
rt G
lass
30
% S
ho
rt G
lass
35
% S
ho
rt G
lass
40
% S
ho
rt G
lass
50
% S
ho
rt G
lass
40
% L
on
g G
lass
50
% L
on
g G
lass
60
% L
on
g G
lass
65
% L
on
g G
lass
PA
6
15
% S
ho
rt G
lass
25
% S
ho
rt G
lass
30
% S
ho
rt G
lass
35
% S
ho
rt G
lass
40
% S
ho
rt G
lass
50
% S
ho
rt G
lass
40
% L
on
g G
lass
50
% L
on
g G
lass
60
% L
on
g G
lass
Mo
du
lus,
GPa
Tensile Modulus
Flexural Modulus
PA 66 PA 6
0
100
200
300
400
500
PA
66
15
% S
ho
rt G
lass
25
% S
ho
rt G
lass
30
% S
ho
rt G
lass
35
% S
ho
rt G
lass
40
% S
ho
rt G
lass
50
% S
ho
rt G
lass
40
% L
on
g G
lass
50
% L
on
g G
lass
60
% L
on
g G
lass
65
% L
on
g G
lass
PA
6
15
% S
ho
rt G
lass
25
% S
ho
rt G
lass
30
% S
ho
rt G
lass
35
% S
ho
rt G
lass
40
% S
ho
rt G
lass
50
% S
ho
rt G
lass
40
% L
on
g G
lass
50
% L
on
g G
lass
60
% L
on
g G
lass
Stre
ngt
h, M
Pa
Tensile Strength
Flexural Strength
PA 6PA 66
Modulus Strength
© 2016 BASF Corporation 15
Ultramid® A Ultramid® B Ultramid® A Ultramid® B
Dry as molded
Parallel trends in flexural and tensile moduli and strength
Modulus independent of fiber lengths in test specimens
0
10
20
30
40
50
60
PA
66
15
% S
ho
rt G
lass
25
% S
ho
rt G
lass
30
% S
ho
rt G
lass
35
% S
ho
rt G
lass
40
% S
ho
rt G
lass
50
% S
ho
rt G
lass
40
% L
on
g G
lass
50
% L
on
g G
lass
60
% L
on
g G
lass
65
% L
on
g G
lass
PA
6
15
% S
ho
rt G
lass
25
% S
ho
rt G
lass
30
% S
ho
rt G
lass
35
% S
ho
rt G
lass
40
% S
ho
rt G
lass
50
% S
ho
rt G
lass
40
% L
on
g G
lass
50
% L
on
g G
lass
60
% L
on
g G
lass
Ch
arp
y Im
pac
t St
ren
gth
, kJ
/m² Notched, Dry, 23C
Notched, Dry, -30C
PA 6PA 66Ultramid® A Ultramid® B
Ultramid® Impact properties
© 2016 BASF Corporation 16
Long fiber advantage → Impact performance
0
0.2
0.4
0.6
0.8
1
1.2
1.4
0.1 1 10 100 1000 10000
Stra
in, %
Time, hPA66 Short Fiber - 40 MPa PA66 Long Fiber - 40 MPa
PA66 Short Fiber - 80 MPa PA66 Long Fiber - 80 MPa
Short/Long Creep Performance
Ultramid® A - 50% glass fiber
Short fiber
Long fiber
Creep performance differences more pronounced
at higher time scales and higher loadings
© 2016 BASF Corporation 17
Cra
ck g
row
th r
ate
0
10
20
30 wt% fibers in PP
Fracture Toughness
Parallel to Flow Direction in
Injection Molded Plaque
Fatigue Behavior
© 2016 BASF Corporation 18
10
100
1000
1 10 100 1000 10000 100000 1000000 10000000Te
nsi
le S
tres
s, M
Pa
Number of Cycles
PA66 Short Glass
PA66 Long Glass
Ultramid® A
50% glass fiber
Fatigue performance extend due to long fibers
creating a fiber network
A. Pegoretti and T. Ricco, “Fatigue fracture of neat and short glass fiber
reinforced polypropylene: effect of frequency and material orientation,"
Journal of Composite Materials, vol. 34, no. 12, pp. 1009-1027, 2000.
Short Glass Fibers Short & Long Glass Fibers
Increasing fiber content increases toughness
while inhibiting crack growth
Fiber Diameter Effects (PA66-30wt% glass)
Average Length Average Aspect Ratio
diameter, µm Ln, mm Lw, mm Ln/d Lw/d
10 0.34 0.55 34 55
11 0.4 0.65 36 59
14 0.49 0.73 35 52
17 0.56 0.79 33 46
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
2
8 10 12 14 16 18
No
rmal
ized
Co
mp
osi
te P
rop
erti
es
Fiber Diameter, µm
Tensile Strength
Tensile Modulus
Tensile Strain
Flexural Strength
Flexural Modulus
Notched Izod Impact Strength
Unnotched Izod Impact Strength
34
36
35
3355
59
52
46
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
8 10 12 14 16 18
Fib
er L
engt
h, m
m
Fiber Diameter, µm
Thomason, "The influence of fibre properties of the performance of glass-fibre-reinforced polyamide 6,6," Composites Science and Technology, vol. 59, pp.
2315-2328, 1999.
Strength – some decrease (14%)
Modulus – no change (2%)
Notched Impact – slight increase (7%)
Unnotched Impact – significant decrease (72%)
© 2016 BASF Corporation 19
0.0
0.5
1.0
1.5
2.0
2.5
3.0
TensileModulus
TensileStrength
Strain atBreak
FlexuralModulus
FlexuralStrength
Charpynotchedimpact
strength
Pro
per
ties
No
rmal
ized
to
40
% S
ho
rt G
lass 40% Short Glass
40% Long Glass
40% Short Carbon
40% Long Carbon
Ultramid® A3W - 40 wt% Short/Long ,
Glass/Carbon Fiber
Typical properties of glass and Carbon fiber Glass Carbon
Density, g/cm3 2.5 – 2.6 1.7 – 1.8 Tensile Modulus, GPa 70 – 80 225 – 275
Tensile Strength, GPa 1.5 – 3.5 2.5 – 5 Elongation at Break, % 0.5 – 2 1.8 – 3.2
© 2016 BASF Corporation 20
Long glass fibers
Impact Properties
Carbon fibers
Stiffness Strength
Relative specific properties to 40% Short Glass
Fiber – Ultramid® A
0
0.5
1
1.5
2
2.5
3
3.5
4
TensileModulus
TensileStrength
Strain atBreak
FlexuralModulus
FlexuralStrength
Charpynotchedimpact
strength
Spec
ific
Pro
per
ties
No
rmal
ized
to
40
% S
ho
rt G
lass
40% Short Glass
40% Long Glass
40% Short Carbon
40% Long Carbon
Specific Property =Property
Composite Density
© 2016 BASF Corporation 21
Advantages of
carbon fiber become
more pronounced for
light-weighting
applications
Long glass fiber
impact properties not
as significant
improvement
Glass and carbon fiber at equal volume% in
polypropylene
0
2
4
6
8
10
12
14
16
0 20 40 60
Ten
sile
Mo
du
lus,
GP
a
Weight %
Short Glass
Short Carbon
0
10
20
30
40
50
60
70
0 20 40 60
Ten
sile
Str
engt
h, M
Pa
Weight %
Short Glass
Short Carbon0
1
2
3
4
5
6
7
0 20 40 60
No
tch
ed C
har
py
Imp
act
Stre
ngt
h,
kJ/m
2
Weight %
Short Glass
Short Carbon
4846
43
39 37
31
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0 20 40 60
Nu
mb
er A
vera
ge F
iber
Len
gth
, mm
Weight %
Short Glass
Short Carbon
Aspect Ratios
Property Carbon Glass
Diameter, µm 7.5 13.8
Tensile Strength, MPa 3950 1956
Tensile Modulus, GPa 238 78.5
S.-Y. Fu, B. Lauke, E. Mäder, C.-Y. Yue and X. Hu, "Tensile properties of short-glass-fiber- and short-carbon-fiber-reinfoced polypropylene composites,"
Composites: Part A, pp. 1117-1125, 2000.
S. Fu, B. Lauke, E. Mäder, X. Hu and C. Yue, "Fracture resistance of short-glass-fiber-reinforced and short-carbon-fiber-reinforced polypropylene under Charpy
impact load and its dependence on processing," Journal of Materials Processing Technology, pp. 501-507, 1999.
© 2016 BASF Corporation 22
Stiffness – translated from fiber properties
Strength & Impact – less driven by fiber properties
more likely aspect ratio & sizing
0
5
10
15
20
25
30
35
40
-40 -20 0 20 40 60 80 100 120 140 160
Ten
sile
Mo
du
lus,
GP
a
Temperature, C
PA66 50% ShortGlassPA66 50% LongGlassPA66 40% ShortCarbonPA66 40% LongCarbonPA66
Dry
Ultramid® Properties with Temperature
© 2016 BASF Corporation 23
PA66
50% Glass
40% Carbon
0
50
100
150
200
250
300
350
-40 -20 0 20 40 60 80 100 120 140 160
Ten
sile
Str
engt
h, M
Pa
Temperature, C
PA66 50% Short Glass
PA66 50% Long Glass
PA66 40% Short Carbon
PA66 40% Long Carbon
PA66
Dry
Fiber network from long fibers improves modulus at elevated temperatures
0
2
4
6
8
10
12
14
16
18
0 10 20 30 40 50 60
Ten
sile
Mo
du
lus,
GP
a
Fiber Content, wt%
Heat Aging Resistant Impact Modified Flame Retardant
Stabilized Stabilized
0
50
100
150
200
250
300
0 10 20 30 40 50 60
Ten
sile
Str
engt
h, M
Pa
Fiber Content, wt%
A3W - High Resistance to Heat AgingA3Z - Impact ModifiedA3X2 - Flame Retardant w/ Red PhosphorusA3E - Resistant to Heat Aging, Weather & Hot WaterA3H - Resistant to Heat Aging, Weather & Hot Water - Engineering Parts
Resin Formulation - Ultramid® A
Short Glass Fiber
Short Glass Fiber
0
5
10
15
20
25
30
35
40
45
0 10 20 30 40 50 60 70N
otc
hed
Ch
arp
y Im
pac
t St
ren
gth
, kJ/
m2
Fiber Content, wt%
Short Glass Fiber
Short Glass Fiber + Impact Modifier
Long Glass Fiber
© 2016 BASF Corporation 24
General trends of property improvement with
concentration appear to be universal
Some additives necessary for the end-use
application can negatively effect properties
General Summary
25
Property Modulus Strength Strain
at
Break
Notched
Impact
Creep Fatigue Performance
at Higher
Temperatures
Increase
Concentration
Increase Fiber
Length-
Carbon Fiber (relative to glass)
-
© 2016 BASF Corporation
*Concentration, length and fiber type are not completely independent variables
Properties in the end-use part are largely influenced by processing:
• Fiber Orientation
• Fiber Length (aspect ratio)
LEGAL DISCLAIMER
WHILE THE DESCRIPTIONS, DESIGNS, DATA AND INFORMATION CONTAINEDHEREIN ARE PRESENTED IN GOOD FAITH AND BELIEVED TO BE ACCURATE, THEYARE PROVIDED FOR GUIDANCE ONLY. BECAUSE MANY FACTORS MAY AFFECTPROCESSING OR APPLICATION/USE, BASF RECOMMENDS THAT THE READERMAKE TESTS TO DETERMINE THE SUITABILITY OF A PRODUCT FOR A PARTICULARPURPOSE PRIOR TO USE. NO WARRANTIES OF ANY KIND, EITHER EXPRESSEDOR IMPLIED, INCLUDING, BUT NOT LIMITED TO, WARRANTIES OFMERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE MADEREGARDING PRODUCTS DESCRIBED OR DESIGNS, DATA OR INFORMATION SETFORTH, OR THAT THE PRODUCTS, DESCRIPTIONS, DESIGNS, DATA ORINFORMATION MAY BE USED WITHOUT INFRINGING THE INTELLECTUALPROPERTY RIGHTS OF OTHERS. IN NO CASE SHALL THE DESCRIPTIONS,INFORMATION, DATA OR DESIGNS PROVIDED BE CONSIDERED A PART OF BASF'STERMS AND CONDITIONS OF SALE. FURTHER, THE DESCRIPTIONS, DESIGNS,DATA, AND INFORMATION FURNISHED BY BASF HEREUNDER ARE GIVEN GRATISAND BASF ASSUMES NO OBLIGATION OR LIABILITY FOR THE DESCRIPTIONS,DESIGNS, DATA OR INFORMATION GIVEN OR RESULTS OBTAINED, ALL SUCHBEING GIVEN AND ACCEPTED AT THE READER'S RISK.
26© 2016 BASF Corporation
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