This paper focuses on the development of swellable thermoplastic elastomer alloys based on elastomeric powder, polypropylene, and superabsorbent polymer. The mechanical and swelling properties of the resulting materials were investigated at varying concentrations of the components and by compatiblization between the rubber particles of the elastomeric powder and the polypropylene phase using the peroxide 2,5-dimethyl-2,5di (t-buthylperoxy)hexane as compatibilizer. The materials obtained could be processed by injection molding in the same way as thermoplastics. The mechanical and swelling properties of the materials could be controlled by shifting the concentrations of the components. The swelling properties in different swelling media were investigated. A maximum of 120% of the relative increase of mass was obtained using KOH solution. The positions of the SAP particles within the material were detected by a combined method of SEM and EDX scan. Elastomeric powder and thermoplastic build the matrix material, in which the SAP particles are embedded mechanically. A schematic illustration of the material structure was developed, and the liquid was suspected to be transported by diffusion into the material matrix as well as along the interface between SAP and the matrix material. The results obtained can be used for the design of improved sealing concepts, as they evidence a good method of using recycled elastomers.

The combination of thin light metal sheets with fibre-reinforced thermoplastic layers in multi-layered fibre-metal-laminates advantageously combines the properties of both material classes. In this way, components can be developed which have both significantly increased specific properties (strength and stiffness with respect to density) and high energy absorption capacity compared with conventional design with mono materials. However, the structural behaviour of crash structures is decisively determined by material behaviour of the thermoplastic and metal constituents as well as the interface properties between both constituents and the corresponding delamination behaviour. To evaluate the structural response of multi-layered fibre-metal-laminates under highly dynamic loading conditions, Charpy tests were performed, where the test parameters, light metal material configuration, support length and laminate thickness, were varied. Moreover, the metal sheet surfaces were pre-treated by embossing to achieve different surface topologies. The influence of the different test parameters on the specific energy absorption capacity was characterised by the analysis of force–displacement curves.

For several years, thermoplastic hybrid laminates form a new class in the field of material compounds. These laminates consist of fibre-reinforced plastic prepregs and metal layers in alternating order. Compared to conventional thermosetting multilayer composites, these laminates are suitable for large-scale production and can be manufactured with significantly reduced cycle times in the thermoforming process.  In the framework of this contribution, the influence of the cooling rate of carbon fibre-reinforced thermoplastic composites and hybrid laminates was investigated with regard to crystallinity and the resulting mechanical properties. Polyamide 6 and thermoplastic polyurethane as matrix systems were examined, in particular.Additionally, the differential scanning calorimetry was used in order to investigate the influence of the cooling rate on the crystallisation behaviour. It could be determined that the cooling rate has a limited influence on the crystallisation of polyamide 6 and this influences the mechanical properties. Furthermore, a reliance of process parameters on the characteristics profile of composite materials and material compounds with thermoplastic polyurethane could be identified. Depending on process conditions, tensile, bending, and interlaminar shear properties fluctuate up to 20 % in fibre-reinforced laminates and up to 32 % in hybrid laminates. Moderate to fast cooling rates result in optimum mechanical characteristics of tensile properties in fibre-plastic-compounds. Fast to very fast cooling rates are advisable for bending and interlaminar shear properties. Highest tensile and bending characteristics are achieved in hybrid laminates by using fast to very fast cooling rates, while interlaminar shear properties tend to be highest in slow to moderate cooling rates.