Influence of the processing on the properties of continuous fiber reinforced thermoplastic sheets prepared by extrusion

Continuous fiber reinforced thermoplastics (CFRT) are composite materials consisting of continuous fibers and a thermoplastic matrix and offer outstanding mechanical properties, low densities, short cycle times and recyclability. CFRT can be classified into unidirectional tapes and sheets utilizing various semi-finished textiles as reinforcement. CFRT sheets are of interest for area measured products or multiaxial loads. Various discontinuous and semi-continuous methods to prepare CFRP sheets are described in the literature. All these methods either feature high cycle times or high investment costs and require double melting of the polymer, e.g., first to produce a polymer film and second to produce the CFRT sheet. An energy efficient alternative to produce CFRT sheets is extrusion, which allows to spare one melting step. A twin-screw extruder melts the polymer, which is then conveyed by a melt pump to the film extrusion dies and applied to both sides of the semi-finished textile, which is wetted and consolidated using a calendar. Due to the high melt viscosity and the line load at the calendar the major challenge is to achieve full void-free impregnation of the semi-finished textile. The mechanical properties of a CFRT sheet are determined by fiber and void volume content. Hence, the influence of the processing conditions on the fiber and void volume content as well as the mechanical properties were examined applying a parametric study of the die temperature, the haul-off speed, and the gap between the calendar rolls. The properties of the extruded CFRT sheets were compared to compression molded sheets. The fiber volume content was directly adjusted by the haul-off speed and the extruder throughput. An increasing die temperature lowers the melt viscosity and results in an increased fiber volume content. Scanning electron microscopy shows complete macro impregnation between the fiber bundles but not completely wetted individual filaments within fiber bundles.