Processing investigation and optimization for hybrid thermoplastic composites

A thermoplastic based composite material is suitable for automobile and aerospace applications. The recyclability of thermoplastic and clean processing further enhance its use. The only limitation encountered in using this material is its high-melt viscosity. Various techniques have been developed to overcome this problem. Commingled materials are one of such methods adopted for making proper use of thermoplastic. A major problem observed during the use of a commingled material is its de-commingling, wherein, the uniform distribution of fiber and thermoplastic yam gets disturbed and affects the final quality of the composite. The effects of the braiding process on laminate quality were investigated. Flat plaques were produced by braiding the commingled yam, using a 48-carrier braiding machine. The braids (and control woven samples) were subsequently heated and consolidated in a nonisothermal compression molding operation. Prior to the manufacture of the ‘best quality’ plaques, a series of moldings were produced under different consolidation conditions, to study the dependence of properties on the process variables. This enabled a processing window to be established for each material and helped to separate the respective effects of yam handling, textile processing, and consolidation on laminate properties.