Thermochemical and rheological characterization of highly reactive thermoset resins for liquid moulding.

Highly reactive thermosets are currently expanding the processability of high-performance structures for transportation industry. The short polymerization time makes it a suitable process to replace metallic structures with polymer matrix-based composite materials. The resin characterization is a fundamental step to obtain the properties and the associated constitutive models, which are required to design and optimize the manufacturing process parameters of composite materials. However, the short time on polymerization requires to use the characterization equipment at their performance capability limits. This work presents a comprehensive methodology to characterize the thermo-chemical properties of highly reactive resin systems, which are relevant for resin impregnation into the preform for liquid injection processes. Four different commercial resin systems are analyzed in this study. Experimental methodologies are analyzed and adapted for best data acquisition at high temperature isothermals. Based on the experimental data, Cure kinetics and viscosity equation-based models are used to describe the behaviour of these complex resin systems. Processing maps are developed based on the cure kinetics and viscosity models to predict the processability time for specific process conditions than can be used on liquid injection moulding processes.

Influence of the reaction stoichiometry on the mechanical and thermal properties of SWCNT-modified epoxy composites.

Previous studies suggest that carbon nanotubes (CNTs) have a considerable influence on the curing behavior and crosslink density of epoxy resins. This invariably has an important effect on different thermal and mechanical properties of the epoxy network. This work focuses on the important role of the epoxy/hardener mixing ratio on the mechanical and thermal properties of a high temperature aerospace-grade epoxy (MY0510 Araldite as an epoxy and 4,4'-diaminodiphenylsulfone as an aromatic hardener) modified with single-walled carbon nanotubes (SWCNTs). The effects of three different stoichiometries (stoichiometric and off-stoichiometric) on various mechanical and thermal properties (fracture toughness, tensile properties, glass transition temperature) of the epoxy resin and its SWCNT-modified composites were obtained. The results were also supported by Raman spectroscopy and scanning electron microscopy (SEM). For the neat resin, it was found that an epoxy/hardener molar ratio of 1:0.8 provides the best overall properties. In contrast, the pattern in property changes with the reaction stoichiometry was considerably different for composites reinforced with unfunctionalized SWCNTs and reduced SWCNTs. A comparison among composites suggests that a 1:1 molar ratio considerably outperforms the other two ratios examined in this work (1:0.8 and 1:1.1). This composition at 0.2 wt% SWCNT loading provides the highest overall mechanical properties by improving fracture toughness, ultimate tensile strength and ultimate tensile strain of the epoxy resin by 40%, 34%, 54%, respectively.