Development of High Performance Thermoplastic Continuous Fibre Composites for Aerospace Automobile and Energy Applications

Abstract

There is a growing interest in adopting high-performance thermoplastic-based composites as an alternative to existing materials such as thermoset composites and metals due to their advantageous attributes, such as low density, superior mechanical capabilities, good chemical and environmental resistance, and recyclable nature. Despite these advantages, the use of high performance thermoplastic-based composites in industry is confined to a few applications. This is essentially the result of two obstacles encountered with the development and adoption of high performance thermoplastic composites. First, the processing of thermoplastic composites, especially continuous fibre composites, is particularly challenging due to the high viscosity of the resin and high processing temperatures. Second, crucial interfacial engineering is necessary to produce an optimal interface between the fibre and resin, without which the requisite mechanical properties of the composite cannot be obtained. The primary objective of this dissertation is to generate fundamental knowledge regarding the processing of high-performance thermoplastic-based continuous fibre composites and their property enhancement by surface modification. The study aims to establish polyetherketone (PEK) as a potential resin for the fabrication of high-performance thermoplastic composites. As a reinforcement for the PEK resin, two distinct woven fibres are being investigated: Carbon Fibre (CF) and PBO fibre. The dissertation addresses the limitation with respect to processing by adopting a less explored method of fabrication known as film fibre stacking and consolidation. In this method, fabric and polymer film are alternately stacked, and the stacks are then consolidated via compression molding to create a laminate. This method is particularly useful for the fabrication of high performance laminates owing to the low travel path for the viscous thermoplastic resin used for impregnating the fibre. The mechanical properties of CF/PEK composites are studied in relation