Chad A. Ulven

Natural Fiber Reinforced Composites

In this review, insight into the use of bio-based fibers as composite reinforcement has been addressed. Specifics on the varieties of natural fibers, and the resultant properties from their constituents and hierarchal structures are described. The methods used to enhance the interface of these fibers with a variety of polymer matrices are reviewed. In addition, the influence of textile operations on creating various fiber architectures with resulting reinforcing capabilities, along with the methods in which natural fiber reinforced composites can be processed, are addressed. Finally, discussion of the correlation between structure, processing, and final composite properties are provided.

Effect of projectile shape during ballistic perforation of VARTM carbon/epoxy composite panels

The use of carbon/epoxy composites in aircraft, marine, and automotive structural applications is steadily increasing. Robust composite structures processed using low-cost techniques with the purpose of sustaining high velocity impact loads from various threats are of great interest. An example of a low-cost process is the out-of-autoclave, vacuum assisted resin transfer molding (VARTM) technique. The present study evaluates the perforation and damage evolution created by various projectile geometries in VARTM processed carbon/epoxy laminates. A series of ballistic impact tests have been performed on satin weave carbon/epoxy laminates of 3.2 and 6.5 mm thickness, with projectile geometries representing hemispherical, conical, fragment simulating and flat tip. A gas-gun with a sabot stripper mechanism was employed to impact the samples with 50-caliber projectiles of the different shapes. The perforation mechanism, ballistic limit, and damage evolution of each laminate has been studied. The influence of projectile shape in the VARTM carbon/epoxy laminates under high velocity impact followed the analytical predictions by Wen [Compos. Struct. 49 (2000) 321; Compos. Sci. Technol. 61 (2001) 1163]. The conical shaped projectile resulted in highest ballistic limit, followed by the flat, hemispherical and the fragment simulating.

A plant fiber reinforced polymer composite prepared by a twin-screw extruder.

Polypropylene (PP) composites reinforced using a novel plant fiber, sunflower hull sanding dust (SHSD), were prepared using a twin-screw extruder. Thermal and mechanical properties of the SHSD/PP composites were characterized and compared to an organically modified clay (organo-clay)/PP composite. Differential scanning calorimetry (DSC) analysis showed that the crystallization temperature and the degree of crystallinity of PP exhibited changes with addition of SHSD and organo-clay. Mechanical properties of the PP were enhanced with the addition of SHSDs. Both the flexural strength and flexural modulus of the PP composites containing 5% (w/w) SHSD were comparable to that of the 5% (w/w) organo-clay reinforced PP. Scanning electron microscope (SEM) observation showed that no obvious agglomeration of SHSD existed in the PP matrix. Compared to the neat PP and organo-clay/PP, the SHSD/PP composites exhibited a relatively decreasing rate of thermal degradation with increase in temperature. Experimental results suggest that SHSD, as a sunflower processing byproduct, may find promising applications in composite materials.

Impact Damage of Partially Foam-filled Co-injected Honeycomb Core Sandwich Composites

The present study considers filling of honeycomb type cores with foam to produce sandwich constructions. The potential benefits of this approach are enhancement of damage resistance, and ability to process honeycomb type sandwich structures through cost-effective vacuum assisted resin transfer molding (VARTM). As weight penalty is incurred in complete filling of honeycomb cells with foam, an alternative approach to reduce weight is partial filling of the cells, without losing the advantage of VARTM processing of the core. Two cores are considered, a polyurethane foam for full filling of honeycomb cells, and syntactic foam for partial filling, in conjunction with carbon–epoxy facesheets. Their impact response was investigated under low and high velocity impact (LVI and HVI respectively). For both cores, the foam filling was found to provide confinement to the cells. The resistance to penetration, energy absorbed and damage modes in LVI and HVI were a function of core stiffness, extent of filling and number of facesheet plies. The results illustrate that partial syntactic foam filled sandwich plate (with reduced weight penalty in comparison to full filling) can provide LVI response improvement in the order of 56% increase in peak load, and for HVI about 74% improvement in ballistic limit.

Production and characterization of epoxidized canola oil.

Epoxidized canola oil may be well suited to the partial replacement of petroleum products in composite matrices; however, a process is needed to obtain this material from canola oil at sufficient conversion and scale to assess product properties. Therefore, canola oil was epoxidized in a solvent-free process with a heterogeneous catalyst; a fractional factorial design was used to determine the impact of processing conditions and their two-factor interactions on epoxy group content of epoxidized canola oil. The studied parameters were: molar ratio of acetic acid to unsaturation, molar ratio of hydrogen peroxide to unsaturation, concentration of hydrogen peroxide, concentration of catalyst, and temperature. Epoxidized canola oil with up to 98.5% conversion was produced. The parameters molar ratio of acetic acid to unsaturation, concentration of hydrogen peroxide, temperature, and their interactions were found to be significant in the defined design space. Process conditions that achieved the highest conversion were scaled to 300 g to compare the conversion, production yield, and rheological and melting properties of products of the epoxidation of both canola and soybean oil with and without solvent. Epoxidized canola oil crystallized at room temperature; at 40°C it was shear-thinning with an apparent viscosity of 140 to 150 mPa·s. Elimination of solvent in the epoxidation process decreased the yield 10% but did not reduce the conversion to epoxy groups. Therefore, the scaled-up, solvent-free process is proposed as a green alternative for sufficient epoxidized canola oil to test composite applications.

Bio-Based Resin Reinforced with Flax Fiber as Thermorheologically Complex Materials

With the increase in structural applications of bio-based composites, the study of long-term creep behavior of these materials turns into a significant issue. Because of their bond type and structure, natural fibers and thermoset resins exhibit nonlinear viscoelastic behavior. Time-temperature superposition (TTS) provides a useful tool to overcome the challenge of the long time required to perform the tests. The TTS principle assumes that the effect of temperature and time are equivalent when considering the creep behavior, therefore creep tests performed at elevated temperatures may be converted to tests performed at longer times. In this study, flax fiber composites were processed with a novel liquid molding methacrylated epoxidized sucrose soyate (MESS) resin. Frequency scans of flax/MESS composites were obtained at different temperatures and storage modulus and loss modulus were recorded and the application of horizontal and vertical shift factors to these viscoelastic functions were studied. In addition, short-term strain creep at different temperatures was measured and curves were shifted with solely horizontal, and with both horizontal and vertical shift factors. The resulting master curves were compared with a 24-h creep test and two extrapolated creep models. The findings revealed that use of both horizontal and vertical shift factors will result in a smoother master curves for loss modulus and storage modulus, while use of only horizontal shift factors for creep data provides acceptable creep strain master curves. Based on the findings of this study, flax/MESS composites can be considered as thermorheologically complex materials.

Long-Term Creep Behavior of Flax/Vinyl Ester Composites Using Time-Temperature Superposition Principle

Natural fibers have great potential to be used as reinforcement in composite materials. Cellulose, being a critical constituent of natural fibers, provides unquestionable advantages over synthetically produced fibers. Increasing demand for use of bio-based composites in different engineering and structural applications requires proper test methods and models for predicting their long-term behavior. In the present work, the time-temperature superposition principle was successfully applied to characterize creep behavior of flax/vinyl ester composites. The creep compliance vs time curves were determined and shifted along the logarithmic time axis to generate a master compliance curve. The time-temperature superposition provided an accelerated method for evaluation of mechanical properties of bio-based composites, and the results suggest that the time-temperature superposition is a useful tool for accelerated testing of long-term behavior of bio-based composites.

Processing and characterization of a polypropylene biocomposite compounded with maleated and acrylated compatibilizers

Polypropylene (PP) biocomposites containing 20 wt.% sunflower hull as a particulate reinforcement were compounded and tested under tensile, flexural, and impact loadings. The incorporation of the sunflower hull without compatibilizer resulted in diminished tensile strength and impact energy absorption but increased flexural strength and both tensile modulus and flexural modulus when compared to neat PP. Formulations containing three different chemical compatibilizers were tested to determine their effectiveness in improving the interfacial adhesion between the fiber surface and PP chains. Maleic anhydride grafted with PP (MA-g-PP) achieved greater improvements in tensile strength but reduced impact strength in comparison to an acrylic-acid-grafted PP compatibilizer (AA-g-PP). The molecular weight, graft level, and the ability to affect strength, modulus, and absorbed impact energy were also investigated for the compatibilizers. A MA-g-PP having high molecular weight and low graft level was most effective in improving the investigated properties of a sunflower hull-reinforced polypropylene biocomposite.

Production of Flax Fibers for Biocomposites

Natural fibers for many and varied industrial uses are a current area of intense interest. Production of these fibers, furthermore, can add to farmer incomes and promote agricultural sustainability. Flax (Linum usitatissimum L.), which has been used for thousands of years, is unparalleled in supplying natural fibers for industrial applications as diverse as textiles and paper, providing high value linseed and fiber from a single plant, and maintaining sustainable agriculture in temperate and subtropical climates for summer or winter production, respectively. As a value-added replacement for glass fiber from a renewable resource, flax fiber is recyclable, biodegradable, and sustainable for the economy, ecology, and society. To the point, DaimlerChrysler reported that natural fibers for automotive components required 83% less energy and were 40% less expensive than glass fiber components. A better understanding of the fiber characteristics that influence composite performance could lead to the development of additives, coatings, binders, or sizing suitable for natural fiber and a variety of polymeric matrices. Stems of flax require retting to separate fiber from nonfiber components and rigorous mechanical cleaning to obtain industrial-grade fibers. Considerable work has been undertaken to improve the retting process using specific cell-free enzymes, especially pectinases, to control and tailor properties for industrial applications. Fiber processing and use in composites are affected by variables such as length, uniformity, strength, toughness, fineness, surface constituents, surface characteristics, and contaminants. One of the main concerns for the composite and other industries in incorporating natural fibers, such as flax, into production parts is the fiber variability resulting from crop diversity, retting quality, and different processing techniques. Standardized methods to assess flax fiber properties, therefore, are needed to maintain quality from crop to crop and provide a means to grade fibers for processing efficiency and applications. Other parts of the plant stalk, notably the waste shive and dust, can potentially be utilized as coproducts to offset costs for producing the major products of fiber and seed.

Modifications Caused by Enzyme-Retting and Their Effect on Composite Performance

Bethune seed flax was collected from Canada with seed removed using a stripper header and straw pulled and left in field for several weeks. Unretted straw was decorticated providing a coarse fiber bundle feedstock for enzyme treatments. Enzyme treatments using a bacterial pectinolytic enzyme with lyase activity were conducted in lab-scale reactors. Four fiber specimens were created: no retting, minimal retting, moderate retting, and full retting. Fiber characterization tests: strength, elongation, diameter, metal content, wax content, and pH were conducted with significant differences between fibers. Thermosetting vinyl ester resin was used to produce composite panels via vacuum-assisted infusion. Composite performance was evaluated using fiber bundle pull-out, tensile, impact, and interlaminar shear tests. Composite tests indicate that composite panels are largely unchanged among fiber samples. Variation in composite performance might not be realized due to poor interfacial bonding being of larger impact than the more subtle changes incurred by the enzyme treatment.