Closed Loop Recycling of CFRP Into Highly Aligned High Performance Short Fiber Composites Using the TUFF Process

Heider, Dirk; Tierney, John; Deitzel, Joseph M.; Kubota, Munetaka; Thiravong, John; Gargitter, Verena; Burris, Winona; Morris, John E.; Shevchenko, N. B.; Yarlagadda, Shridhar; Gillespie, John W.

doi:10.33599/nasampe/s.19.1607

Cited by 9 publications

(5 citation statements)

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“…Several other authors have pursued other alignment methods with varying degrees of success. For example, Heider et al [45] reported on the Tailorable Universal Feedstock for Forming (TuFF) process at the University of Delaware in 2019. Little information regarding the process is available, but the resulting preforms exhibit fiber alignment of 94% within ±5 • of the loading axis for fibers 3 mm in length [46].…”

Section: Highly Aligned Preformsmentioning

confidence: 99%

“…Moderate mechanical properties were achieved, with roughly 70% of fibers oriented between ±15 • to the loading axis. Meanwhile, a highly aligned preform known as Tailorable Universal Feedstock for Forming (TUFF) was developed at the University of Delaware [45,46]. IM-7 carbon fibers of 3 mm length were used to produce 8 gsm textiles that were consolidated with a polyetherimide (PEI) resin to produce composites in an autoclave with up to 63% fiber volume fraction and alignment of 94% of fibers within ±5 • of the loading axis.…”

Section: Highly Aligned Preformsmentioning

confidence: 99%

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A Review of Recent Developments in Composites Made of Recycled Carbon Fiber Textiles

Barnett

Ghossein

2021

Textiles

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Carbon fiber recycling has garnered significant attention in recent years due to the large volume of manufacturing waste and upcoming end-of-life products that will enter the waste stream as the current generation of aircraft is retired from service. Recycled carbon fibers have been shown to retain most of their virgin mechanical properties, but their length is generally reduced such that continuous fiber laminates cannot be remade. As such, these fibers are typically used in low-performance applications including injection molding, extrusion/compression molding, and 3D printing that further degrade the fiber length and resulting composite properties. However, recent advances in the processing of long discontinuous fiber textiles have led to medium- to high-performance composites using recycled carbon fibers. This review paper describes the recent advances in recycled carbon fiber textile processing that have made these improvements possible. The techniques used to manufacture high-value polymer composites reinforced with discontinuous recycled carbon fiber are described. The resulting mechanical and multifunctional properties are also discussed to illustrate the advantages of these new textile-based recycled fiber composites over the prior art.

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Section: Highly Aligned Preformsmentioning

confidence: 99%

Section: Highly Aligned Preformsmentioning

confidence: 99%

A Review of Recent Developments in Composites Made of Recycled Carbon Fiber Textiles

Barnett

Ghossein

2021

Textiles

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“…In additional investigations, the deformation limits of the TuFF material were examined with respect to strain rate and strain deformation at temperatures of 280, 300, 310, 320, and 330 • C. It was observed that the material exhibits lower levels of strain at high strain rates, leading to premature failure. By reducing the strain rate, higher levels of strain could be achieved, as the material had sufficient time to relax [45][46][47][48][49][50].…”

Section: Introductionmentioning

confidence: 99%

New Approach for Processing Recycled Carbon Staple Fiber Yarns into Unidirectionally Reinforced Recycled Carbon Staple Fiber Tape

Detzel,

Mitschang,

Breuer

2023

Polymers

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This study describes a novel process in which staple fiber yarns made from recycled carbon fibers (rCFs) and polyamide 6 (PA6) fibers are further processed into semi-finished tape products in a modified impregnation and calendaring process. In this process, the staple fiber yarns are heated above the melting temperature of the polymer, impregnated, and stretched to staple fiber tapes (SF tapes) in the calendaring unit. SF tapes with different degrees of stretching and/or repasses were produced. The individual width and thickness were measured in line by a laser profile sensor. From these tapes, preforms were manually laid and processed into laminates in an autoclave. The important physical properties of the unidirectionally reinforced laminates made of the tapes were compared with organic sheets wound from staple fiber yarns. With increasing stretching, both the fiber orientation and mechanical properties improved compared to the organic sheets made from unstretched staple fiber yarns. An improvement in fiber orientation relative to the process direction from 66.3% to 91.9% (between ±10°) and 39.1% to 71.6% (between ±5°), respectively, was achieved for a two-stage stretched tape. The tensile and flexural moduli were increased by 15.2% and 14.5%, respectively.

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“…Alternatively, rCFs can be remanufactured into chopped strand mats [18] or nonwoven mats through processes analogous to wet paper-making [19] or carding, cross-lapping, and needling [20], which can be subsequently spun into yarn [21,22]. However, the best mechanical performance, and therefore the highest value, is achieved following the realignment of the short rCFs with techniques such as the Centrifugal Fibre Alignment Drum developed at the University of Nottingham [23], the Tailorable Feedstock for Forming from the University of Delaware [24], and the High Performance Discontinuous Fibre (HiPerDiF) technology invented at the University of Bristol [25], which forms the basis of the current study.…”

Section: Introductionmentioning

confidence: 99%

Life Cycle Assessment of the High Performance Discontinuous Fibre (HiPerDiF) Technology and Its Operation in Various Countries

et al. 2022

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Composite waste is a growing issue due to the increased global demand for products manufactured from these advanced engineering materials. Current reclamation methods produce short length fibres that, if not realigned during remanufacture, result in low-value additives for non-structural applications. Consequently, to maximise the economic and functional potential, fibre realignment must occur. The High Performance Discontinuous Fibre (HiPerDiF) technology is a novel process that produces highly aligned discontinuous fibre-reinforced composites, which largely meet the structural performance of virgin fibres, but to date, the environmental performance of the machine is yet to be quantified. This study assessed the environmental impacts of the operation of the machine using life cycle assessment methodology. Electrical energy consumption accounts for the majority of the greenhouse gas emissions, with water consumption as the main contributor to ecosystem quality damage. Suggestions have been made to reduce energy demand and reuse the water in order to reduce the overall environmental impact. The hypothetical operation of the machine across different European countries was also examined to understand the impacts associated with bulk material transport and electricity from different energy sources. It was observed that the environmental impact showed an inverse correlation with the increased use of renewable sources for electricity generation due to a reduction in air pollutants from fossil fuel combustion. The analysis also revealed that significant reductions in environmental damage from material transport between the reclamation facility to the remanufacturing site should also be accounted for, and concluded that transportation routes predominantly via shipping have a lower environmental impact than road and rail haulage. This study is one of the first attempts to evaluate the environmental impact of this new technology at early conceptual development and to assess how it would operate in a European scenario.

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Closed Loop Recycling of CFRP Into Highly Aligned High Performance Short Fiber Composites Using the TUFF Process

Cited by 9 publications

References 0 publications

A Review of Recent Developments in Composites Made of Recycled Carbon Fiber Textiles

A Review of Recent Developments in Composites Made of Recycled Carbon Fiber Textiles

New Approach for Processing Recycled Carbon Staple Fiber Yarns into Unidirectionally Reinforced Recycled Carbon Staple Fiber Tape

Life Cycle Assessment of the High Performance Discontinuous Fibre (HiPerDiF) Technology and Its Operation in Various Countries

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