A review on Air-Jet Textured Yarn Spinning Technology (ATY) in the global textile industry

Abstract

In this theoretical review study included Air-Jet Textured Yarn spinning technology (ATY); its importance, formation mechanism principle, yarns used, and general properties were explained in detail, supported by images and tables from various sources. Moreover, the specific ATY yarn process parameters required for ATY yarn production and the quantitative values ​​of these process parameters were presented. Finally, the effects of ATY yarn types, and various ATY yarn process parameters on the thermal comfort, physical, and mechanical properties of textile-based woven, and knitted fabrics were explained. According to the results included ATY yarn production machines produced by DuPont and Heberlain Companies have generally used for the production of ATY yarns nowadays. Moreover, multi-jet systems (4 jets) called the Taslan have widely used because they affect the air pressure values, and air-flow regime more homogeneously in various yarn formation axes. Effective technical parameters for ATY yarn production are jet (nozzle) type, jet (nozzle) angle (°), overfeed ratio, amount of compressed air-flow (volumetric air-flow ratio), number of air-jets (nozzles), air-jet inner diameter (mm), production speed (m/min), heater and cooling plate temperatures (°C), times, lengths (mm), inner diameters, pre-tension values, types, and cross-sections of yarns and filaments, wetting of the yarn and the elasticity modulus of the deflection ball of the yarn (N/mm2). Additionally, FDY structure, yarn count (dtex)/filament count from 80/24 to 1666/1000, overfeed ratio value from 5.5 to 36, air pressure value from 7 bar to 10 bar, production speeds from 300 m/min to 500 m/min, a draft ratio value of between 1.75 and 2.19, and a temperature value of 180 °C to 200 °C are generally used in the production of ATY yarns. Texturing property (bulky volume), instability, and mass loss increase, but tensile strength decreases as air pressure increases. These effects are more evident in fine yarn counts (dtex). Tensile strength increases, but instability, and mass loss decrease as the texturing speed increases. Water consumption has no effect on the physical, mechanical, and thermal comfort properties of both woven, and knitted fabrics with ATY yarn structures. POY and FDY structured PET, PA 6, PA 6.6, PP, PI, CV, CO, CMD, PPD-T, and EA yarns are used in the production of ATY yarns. ATY yarns are widely used in home textiles, clothing, airbags, carpets, and upholstery fabrics. The multi-lobed section PET ratio should be high for high bursting strength, tensile strength, air permeability, maximum breaking force, texturing property (bulky volume) and linear density of the yarn values, high shear strength, maximum percent elongation at break, thermal conductivity, pilling resistance. The ratio of CMD, CV, PA 6, or PA 6.6 should be high for water vapor permeability values. The CO ratio should be high for high thermal resistance. The PET ratio should be high for high abrasion resistance values. Shear strength, maximum percent elongation at break, elastic recovery behavior, and abrasion resistance increase as the EA ratio increases. ATY yarns have lower tensile strength, maximum breaking force, maximum percent breaking elongation, breaking work, and abrasion resistance values compared to ring, and OE rotor yarns (except DTY), respectively. The issue of recycling is extremely important for the sustainability of the global textile industry in the future. For this important issue, textile waste must be classified, collected, and evaluated. Moreover, optimization of various experimental production process parameters should be ensured in order to preserve the mechanical properties of blended yarns, especially CO/PET, and CO/PA yarn structures, by reducing chemical, water, energy, and labor costs.