The influence of various kinds of PA12 interlayer on the interlaminar toughness of carbon fiber-reinforced epoxy composites

Modifying the impact toughness of carbon fiber‐reinforced epoxy composites by introducing thermoplastic inserts in the interlaminar layer is state‐of‐the‐art. This article compares the introduction of thermoplastics in continuous and discontinuous form. Test plate samples were produced using unidirectional noncrimp carbon fabrics with two different aircraft resin systems: HEXFLOW RTM6 (Hexcel) and Cycom 890 RTM (Cytec). In addition, Polyamide 12 (PA12) was laid in the interlaminar layer in the forms of two different laid scrims, as powder or as nonwoven fabric (NWF). The performance of the resulting combinations was assessed by testing the samples in Mode I and II interlaminar fracture toughness (GIc and GIIc), interlaminar shear strength (ILSS), and compression strength after impact (CAI). The results show that in nearly all the tests a fine‐mesh laid scrim performs similarly to a NWF with twice the weight per surface area. They show furthermore that the curing dynamics of the resin systems together with the melting characteristics of the thermoplastic during processing have an important effect on the performance of the test samples. Hardening of the resin before the PA12 reaches its melting point hinders the compacting of the thermoplastic. This limits the reduction in the original thickness of the insert, leading to an increase in the sample thickness and, thus, reducing the fiber volume content. Otherwise, the discrete arrangement of the laid scrim has positive effects on the material properties of the composite at elevated temperatures, considerably reducing the falloff in ILSS resulting from the temperature‐dependent Young's modulus of PA12. POLYM. COMPOS., 36:1249–1257, 2015. © 2014 Society of Plastics Engineers