The effect of processing on the mechanical properties of self-reinforced composites

Hot-compaction is one of the most common manufacturing methods for creating recyclable all thermoplastic composites. The current work investigates the compaction of highly oriented self-reinforced fabrics with three processing methods to study the effect of pressure and temperature in the tensile mechanical properties of the consolidated laminates. Hot-press, calender roller and vacuum bag technique were adopted to consolidate bi-component polypropylene woven fabrics in a range of pressures and compaction temperatures. Hot-pressed samples exhibited the highest quality of compaction. The modulus of the hot-pressed samples increased with compaction temperature initially due to the improved interlayer bonding and decreased after a maximum at 150°C because of partial melting of the reinforcement phase. The calender roller technique exhibited to have smaller processing temperature window as the pressure is only applied for a short time and the fabrics start to shrink with increasing the processing temperature. The need for constraining the fabrics through the process is therefore found to be paramount. The Vacuum bag results showed this technique to be the least efficient method because of the low compaction pressure. Microscopic images and void content measurement of the consolidated samples further validate the results from tensile testing.