M-RECT

Multiscale reinforcement of semi-crystalline thermoplastic sheets and honeycombs

 Partecipanti

Mappa

 Word cloud

Esplora la "nuvola delle parole (Word Cloud) per avere un'idea di massima del progetto.

 Obiettivo del progetto (Objective)

'The M-RECT project aims to create multiscale-reinforced semi-crystalline thermoplastics (PEEK and PPS), which will outperform all reinforced polymers in terms of strength, stiffness, creep and mainly damping by upscaling and further developing state of the art production methods, within cost-efficient manufacturing routes. The envisaged multiscale reinforcement will comprise of dispersed straightened and aligned to polymer molecules multi-walled carbon nanotubes (CNTs) and also fully impregnated, long carbon fibres (CF). In order to achieve this objective a number of novel technological achievements including CNT functionalization techniques, fluid-assisted CNT alignment, microwave and induction heating of composites, out of autoclave manufacturing including bagging techniques, DIRIS sandwich panel production, fluoropolymer radiation-absorbing coatings and polymer optical fibre technology will be further developed and used. The CNT or multi-scale reinforced PEEK or PPS sheets and the resulting sandwich panels will be used as raw material for manufacturing laminated complex prototypes covering a wide range of industrial applications such as automotive, railroad, aeronautical, space, civil engineering and biomedical. Optimized design of these structures will be based on suitably developed numerical modelling and optimization tools within the proposed project and which will be validated through extensive testing at nano, meso and macro-scale. The anticipated impacts of the development of the envisaged top-performance lightweight thermoplastic composites and their manufacturing routes will extend to an international level by decreasing energy and fuel consumption, decreasing waste production and improving recyclability, creating profitable spin-off activities, promoting safety and improving the urban environment.'

Introduzione (Teaser)

Reinforced polymers are used in the automotive and aerospace industries as well as for civil infrastructure such as bridges and railroads. Novel composites exploiting functionalised carbon nanotubes (CNTs) could provide major benefits in the future.

Descrizione progetto (Article)

Most laminates used in industries are now based on fibres dispersed in a continuous phase polymer matrix. The EU-funded project 'Multiscale reinforcement of semi-crystalline thermoplastic sheets and honeycombs' (http://mrect.risk-technologies.com/ (M-RECT)) set out to create novel thermoplastics incorporating functionalised CNTs that outperform other reinforced polymers. The project covered the entire supply chain from CNT functionalisation to aid their dispersion in polymeric matrices, to finished component design, manufacturing, testing and use.

Scientists developed technologies resulting in successful functionalisation of CNTs and improved dispersion. The functionalisation processes are scalable and resulted in a patent application. Composite laminates based on the thermoplastic polymers polyetheretherketone (PEEK) and polyphenylene sulphide were manufactured from the novel materials. These polymers are recyclable because unlike thermoset polymers, they can be reheated and reshaped into desired forms over and over. The team produced the laminates with both conventional manufacturing approaches as well as a novel impregnation technology for which a patent application was filed.

The team evaluated the mechanical properties and damage tolerance of these materials. Fracture toughness of the PEEK-CNT composites was improved compared to laminates without CNTs. Simulation results using models developed within the M-RECT project were in good correspondence with test results on validation components. The models will be valuable in guiding future development campaigns.

Multifunctional honeycombs such as the curved, centre-symmetric SILICOMB structure are gaining interest for their enhanced structural integrity and light weight. Investigators also developed a variety of novel morphing honeycomb systems based on SILICOMB. These could offer important benefits in insulation and reduced fuel consumption, and development will continue in a follow-up project.

In addition to materials development, the team created a technology for damage assessment that can be moulded into a thermoplastic composite for structural health monitoring. In addition, scientists produced a tool for risk evaluation that has been distributed to consortium members for use during future development work.

M-RECT has stimulated the development and use of novel thermoplastic composites exploiting functionalised CNTs. Adoption of the new materials could have important environmental and economic impact related to manufacturing, use and recycling.