Correlation between the activation energy of PLA respectively PLA/starch composites and mechanical properties with regard to differ accelerated aging conditions.

Within this research semi-crystalline polylactide and composites with 50 wt.% native potato starch were compounded and injection molded. The material was mechanically characterized by tensile, three-point bending, and Charpy impact tests. These tests were carried out in the freshly molded state and after 332 and 792 h of storage at accelerated temperature or humidity. The respective activation energy was calculated by applying the Flynn-Wall-Ozawa method. The focus of the study was to investigate the correlation between the activation energy and the related mechanical and thermal properties. The results showed that the addition of native potato starch as a filler prevents the decrease in activation energy over the course of the experiments. Thus, the PLA/starch composite is more resistant to the two aging conditions than the pure PLA. When considering the mechanical properties, the pure PLA showed a large deviation of results compared to the initial value in a range of +63.88% to -33.96% with regard to the respective aging conditions, whereas the PLA/starch composite properties nearly always remained at the initial values. Through the investigation of the mechanical and thermal properties, it was shown that the steady activation energies are consistent with the mechanical properties, as these have shown only a small deviation of the mechanical properties during the duration of experiments for the PLA/starch composite.

Influence of Ethylene Oxide and Gamma Irradiation Sterilization Processes on the Properties of Poly-L-Lactic-Acid (PLLA) Materials.

In order to encourage the substitution of petrochemical polymers in medical technology with sustainable, bio-based materials, there is an urgent need for further investigations, especially data regarding their sterility performance. Within the scope of the investigations, selected material properties of poly-L-lactic-acid (PLLA), a specific type of poly(lactic-acid) (PLA), were analyzed before and after sterilization (using ethylene oxide or gamma irradiation) in order to investigate deviations in its chemical structure, wettability, optical, and mechanical properties. In particular, parameters such as molecular weight, complex viscosity, tensile strength, water contact angle, and color were discussed. Sterilization temperatures close to the glass transition of PLA, high humidity, and interactions with the ethylene oxide molecules have resulted in an increase in crystallinity, a decrease in elongation at break, and in some cases, a variation in wettability. As a consequence of exposure to high-energy radiation, the material's toughness is reduced due to chain scission, which is manifested through a decrease in molecular weight, an increase in crystallinity, and a partial change in surface energy. For the selected PLLA-materials (Luminy® L130, NP HT 202, and NP HT 203), ethylene oxide sterilization resulted in a comparatively minor variation in the characteristics behavior, and was chosen as the preferred method.

Influence of Accelerated Aging on the Fiber-Matrix Adhesion of Regenerated Cellulose Fiber-Reinforced Bio-Polyamide.

With regard to the sustainability and biological origin of plastic components, regenerated cellulose fiber (RCF)-reinforced polymers are expected to replace other composites in the future. For use under severe conditions, for example, as a housing in the engine compartment, the resistance of the composites and the impact on the fiber and fiber-matrix adhesion must be investigated. Composites of bio-polyamide with a reinforcement of 20 wt.% RCF were compounded using a twin-screw extruder. The test specimens were manufactured with an injection molding machine and aged under conditions of high humidity at 90% r. H, a high temperature of 70 °C, and water storage using a water temperature of 23 °C for 504 h. Mechanical tests, single-fiber tensile tests (SFTT), single-fibre pull-out tests (SFPT), and optical characterization revealed significant changes in the properties of the composites. The results of the SFPT show that accelerated aging had a significant effect on the bio-polymer and an even stronger effect on the fiber, as the single-fiber tensile strength decreased by 27.5%. Supplementary notched impact strength tests revealed a correlation of the impact strength and the accelerated aging of the RCF-reinforced composites. In addition, it could be verified that the tensile strength also decreased at about 37% due to the aging effect on the RCF and a lowered fiber-matrix adhesion. The largest aging impact was on the Young's modulus with a decrease of 45% due to the accelerated aging. In summary, the results show that the strengthening effect with 20 wt.% RCF was highly decreased subsequent to the accelerated aging due to hydrolysis and debonding because of the shrinkage and swelling of the matrix and fiber. These scientific findings are essential, as it is important to ensure that this bio-based material used in the automotive sector can withstand these stresses without severe degradation. This study provides information about the aging behavior of RCF-reinforced bio-based polyamide, which provides fundamental insights for future research.

Modification of Polyamide 66 for a Media-Tight Hybrid Composite with Aluminum.

Metal-plastic composites are becoming increasingly important in lightweight construction. As a combination, e.g., for transmission housings in automobiles, composites made of die-cast aluminum housings and Polyamide 66 are a promising material. The interface between metal and plastic and the properties of the plastic component play an important role with regard to media tightness against transmission oil. The mechanical properties of the plastic can be matched to aluminum by glass fibers and additives. In the case of fiber-reinforced plastics, the mechanical properties depend on the fiber length and their orientation. These structural properties were investigated using computer tomography and dynamic image analysis. In addition to the mechanical properties, the thermal expansion coefficient was also investigated since a strongly different coefficient of the joining partners leads to stresses in the interface. Polyamide 66 was processed with 30 wt% glass fibers to align the mechanical and thermal expansion properties to those of aluminum. In contrast to the reinforcement additives, an impact modifier to improve the toughness of the composite, and/or a calcium stearate to exert influence on the rheological behavior of the composite, were used. The combination of the glass fibers with calcium stearate in Polyamide 66 led to high stiffnesses (11,500 MPa) and strengths (200 MPa), which were closest to those of aluminum. The coefficient of thermal expansion was found to be 6.6 × 10-6/K for the combination of Polyamide 66 with 30 wt% glass fiber and shows a low expansion exponent compared to neat Polamid 66. It was detected that the use of an impact modifier led to less orientated fibers along the injection direction, which resulted in lower modulus and strength in terms of mechanical properties.

Influence of Different Hot Runner-Systems in the Injection Molding Process on the Structural and Mechanical Properties of Regenerated Cellulose Fiber Reinforced Polypropylene.

The increasing demand for renewable raw materials and lightweight composites leads to an increasing request for natural fiber composites (NFC) in series production. In order to be able to use NFC competitively, they must also be processable with hot runner systems in injection molding series production. For this reason, the influences of two hot runner systems on the structural and mechanical properties of Polypropylene with 20 wt.% regenerated cellulose fibers (RCF) were investigated. Therefore, the material was processed into test specimens using two different hot runner systems (open and valve gate) and six different process settings. The tensile tests carried out showed very good strength for both hot runner systems, which were max. 20% below the reference specimen processed with a cold runner and, however, significantly influenced by the different parameter settings. Fiber length measurements with the dynamic image analysis showed approx. 20% lower median values of GF and 5% lower of RCF through the processing with both hot runner systems compared to the reference, although the influence of the parameter settings was small. The X-ray microtomography performed on the open hot runner samples showed the influences of the parameter settings on the fiber orientation. In summary, it was shown that RCF composites can be processed with different hot runner systems in a wide process window. Nevertheless, the specimens of the setting with the lowest applied thermal load showed the best mechanical properties for both hot runner systems. It was furthermore shown that the resulting mechanical properties of the composites are not only due to one structural property (fiber length, orientation, or thermally induced changes in fiber properties) but are based on a combination of several material- and process-related properties.

Influence of Fiber Volume in Hybrid Short Glass/Cellulose Reinforced Thermoplastic Compounds.

Glass fibers (GF) and regenerated cellulose fibers (RCF) are possible partners in the hybrid reinforcement of thermoplastics because of their different properties. Due to the weak bonding properties of polypropylene, coupling agents are used and the fiber volume content is set high to achieve high reinforcing effects. A lower fiber content of GF can raise the toughness properties of a reinforced polypropylene which is investigated in this study with different ratios of GF and RCF. The composites are tested in tensile tests, flexural tests and also in notched Charpy impact tests. The results can be used to compare whether a substitution of GF with RCF or the addition of more GF leads to higher mechanical properties. The tensile and Charpy impact results are compared with the Rule of Hybrid Mixtures (RoHM) to show the deviation to the prediction. Better results in terms of stiffness and strength are seen with a higher total fiber volume, while hybrid reinforced specimens show lower toughness values compared to the RCF reinforced reference specimens. Adding 5 vol% GF to 16 vol% RCF results in an increase in tensile strength by 26%, but also a significant decrease in elongation at break by 65%.

Demonstration of Hybrid Effect in Single Fiber Pull-Out Tests for Glass/Cellulose-Reinforced Polypropylene with Different Fiber-Matrix Adhesions.

In hybrid fiber reinforcement, the combination of glass and regenerated cellulose fibers is a promising combination because the different properties of the fibers can be combined. The properties of the regenerated cellulose fiber in combination with the absorption of energy by fiber pull-outs can thus significantly increase the toughness of the composite in the event of failure, while the glass fiber significantly increases the stiffness and strength due to its properties. In this study, the interaction of the two fiber types in a composite is demonstrated by fiber pull-outs. For this purpose, the fibers are embedded in a PP matrix and simultaneously pulled out. Different bondings of the fiber by, e.g., coupling agent and/or a pretreatment of the regenerated cellulose fiber, were also investigated. The results show that each type of fiber has a characteristic force-deformation curve, and the hybrid reinforcement is a combination of both curves. The use of a coupling agent leads to an increase in the interfacial shear stress from 4.5 to 7.5 MPa. A treatment of the regenerated cellulose fiber by UV light further increases the interfacial shear stress to 11 MPa.

Effect of Cell Morphology on Flexural Behavior of Injection-Molded Microcellular Polycarbonate.

The quantitative study of the structure and properties relationship in cellular materials is mostly limited to cell diameter, cell density, skin layer thickness, and cell size distribution. In addition, the investigation of the morphology is generally carried out in two dimensions. Therefore, the interrelation between morphological properties and mechanical characteristics of the foam structure has remained in an uncertain state. In this study, during the physical foaming process, a foam morphology is locally created by using a mold equipped with a core-back insert. The variation in morphology is obtained by modifying the mold temperature, injection flow rate, and blowing agent content in the polymer melt. X-ray microtomography (µCT) is used to acquire the 3D visualization of the cells structure. The Cell Distribution Index (CDI) is calculated to represent the polydispersity in cell size distribution. The relationship between the wide range of morphological qualities and relevant flexural properties is made explicit via a statistical model. According to the results, the morphology, particularly cell shape, characterizes the mechanism of the linear elastic deformation of the closed-cell foams. IR-thermography reveals the bending failure of cellular structures in the tensile region despite the differences in cell diameter.

Constant Temperature Approach for the Assessment of Injection Molding Parameter Influence on the Fatigue Behavior of Short Glass Fiber Reinforced Polyamide 6.

Short glass fiber reinforced plastics (SGFRP) offer superior mechanical properties compared to polymers, while still also enabling almost unlimited geometric variations of components at large-scale production. PA6-GF30 represents one of the most used SGFRP for series components, but the impact of injection molding process parameters on the fatigue properties is still insufficiently investigated. In this study, various injection molding parameter configurations were investigated on PA6-GF30. To take the significant frequency dependency into account, tension-tension fatigue tests were performed using multiple amplitude tests, considering surface temperature-adjusted frequency to limit self-heating. The frequency adjustment leads to shorter testing durations as well as up to 20% higher lifetime under fatigue loading. A higher melt temperature and volume flow rate during injection molding lead to an increase of 16% regarding fatigue life. In situ X-ray microtomography analysis revealed that this result was attributed to a stronger fiber alignment with larger fiber lengths in the flow direction. Using digital volume correlation, differences of up to 100% in local strain values at the same stress level for different injection molding process parameters were identified. The results prove that the injection molding parameters have a high influence on the fatigue properties and thus offer a large optimization potential, e.g., with regard to the component design.

Comparison of Real and Simulated Fiber Orientations in Injection Molded Short Glass Fiber Reinforced Polyamide by X-ray Microtomography.

During injection molding of short glass fiber reinforced composites, a complex structure is formed due to the fiber movement. The resulting fiber orientation can be predicted using various simulation models. However, the models are known to have inadequacies andthe influence of process and model parameters is not clearly and comprehensively described. In this study, the aforementioned model and process parameters are investigated to determine the dependencies of the individual influences on the real and simulated fiber orientation. For this purpose, specimens are injection molded at different process parameters. Representative regions of the specimens are measured using X-ray microtomography and dynamic image analysis to determine the geometric properties of the fibers as well as their orientations. Furthermore, simulations are performed with the simulation software Moldflow® using different mesh types and densities as well as varying parameters of the MRD model to represent the real fiber orientations. The results show that different orientation areas arise in the samples, which cannot be represented with a simulation varying only one parameter. Several simulations must be carried out in order to represent flow regions occurring in the specimen as realistically as possible.