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Thermo-mechanical characterisation of polycarbonate-based sheet moulded composites fabricated from off-cut waste unidirectional tapes
Chethan Savandaiah, Andreas Kapshammer, Bernhard Plank, Vanja Stolcer, Christian Marschik, Zoltan Major
Vol. 18., No.9., Pages 883-900, 2024
DOI: 10.3144/expresspolymlett.2024.66
Corresponding author: Chethan Savandaiah

GRAPHICAL ABSTRACT

ABSTRACT

Thermoplastic (TP) composites, known for their ease of handling, suitability for high production rates, and recyclability, are emerging as a promising alternative to thermoset-based composites. The expected growth in TP-based composites in automotive, sports, and aerospace industries may result in increased post industrial waste. To address this, we repurposed our in-house process scrapped carbon fibre-reinforced polycarbonate tapes into sheet moulding compounds (SMCs) and Hybridised SMCs (Hy-SMCs) using compression moulding. In Hy-SMCs, the top and bottom layers were unidirectional tapes, while the core section had randomly oriented platelets in a 50:50 ratio. Our evaluation included qualitative and thermo-mechanical standard tests. The incorporation of unidirectional tapes in Hy-SMCs significantly improved the tensile and flexural properties of SMCs. Specifically, these enhancements resulted in an impressive 81 to 85% increase in mechanical strength compared to the standard aluminium grade. Additionally, Hy-SMCs exhibited a 120 to 130% increase in tensile and flexural properties compared to SMCs. Fractography revealed a complex relation between fractured surfaces, with multimode failures in both SMCs and Hy-SMCs. Also, the non-destructive evaluation showed platelet reorientation during consolidation and localised voids with increased specimen thickness.


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Published by:

Budapest University of Technology and Economics,
Faculty of Mechanical Engineering, Department of Polymer Engineering