Effect of PEEK degradation on commingled fabrics consolidation

Abstract

The effects of PEEK degradation on consolidation of commingled semi-finished products have been investigated. Two commingled semi-finished products provided by two different suppliers have been studied and compared to a powdered fabric based on the same PEEK grade. Both were manufactured from aligned AS4 carbon and PEEK yarns but the first product referred as the NCF1 has a lower commingling level than the second one identified as the NCF2. Contrary to what could be expected, under the same processing conditions, consolidation of the NCF1 and the NCF2 systematically results in a high porosity content, above 10%. Fourier Transform Infrared spectrophotometry (FTIR) in ATR mode and Gel Permeation Chromatography (GPC) have shown small molecular structure modifications of PEEK yarns compared to the raw material, such as a shift of molar mass distributions towards lower molar mass and the appearance of C-H absorption bands attributed to non-aromatic alkanes. These modifications have been attributed to sizing of PEEK filament. Calorimetric (DSC) and rheological analyses have demonstrated that the presence of sizing in the semi-finished products have huge consequences on the degradation kinetics. The crystallization temperature decreases and the viscosity increases significantly. This acceleration of the degradation kinetics is the reason of the poor consolidation behavior during composite manufacturing. The conditions of melt spinning extrusion under which the neat PEEK is transformed into filament are therefore a key factor of PEEK degradation.

Process parameter–mechanical property relationships and influence mechanism of advanced CFF/PEEK thermoplastic composites

“…However, when the molding temperature increases to 400°C, the viscosity of PEEK in the first 12 min is similar to that at 390°C, but then increases rapidly, which can be attributed to the rapid crosslinking of PEEK macromolecular chains exacerbated by excessively high temperature. [ 23,29,30 ] The cross‐section, fracture and surface morphology of the corresponding CFF/PEEK composites confirmed this guess. The rapid increase of PEEK viscosity hinders the effect of CF fabrics being impregnated, resulting in local resin‐rich areas appearing inside the CFF/PEEK composites, as shown in Figure 8D.…”