viii Contents and Subject Index 3.M0RPH0L0GY.,··,····,,,,.53 3.1 Introduction.··.·,.·..,...53 3.2 Factors Influencing Morphology of Semi-Crystalline Thermoplastics..............53 3.2.1 Processing Conditions...,.............,,.................,..53 3.2.2 Foreign Surfaces..,...........,.......,,,,,,.,..,.......58 3.3 Morphology-Property Relationships of Semi-Crystalline Thermoplastics..·········.60 3.4 Summary.················ 4.PERFORMANCE OF THERMOPLASTIC BASED COMPOSITES·,,,·,,,..·.,··.,.67 4.1 Introduction...... .. 4.2 Room Temperature Mechanical Properties..··..··.·············· ···.67 4.3 Elevated Temperature Mechanical Properties··,············· ···.75 4.4 Damage Resistance and Tolerance.,..,..,.,..·.·.,.,·.··.·· ··..78 4.4.1 Interlaminar Fracture Toughness ...................... ·。.78 4.4.2 Delamination Behavior.,,.,:,,,·,,,,·,············· ·。.81 4.4.3 Damage Tolerance.,,·。·············,········'''' ····.83 4.5 Fatigue Resistance.························ ····.86 4.6 Time-Dependent Behavior........ 4.7 Resistance to Thermal Cycling and lonizing Radiation.......................91 4.7.1 Thermal Cycling................,,.,.....91 4.7.2 Electron Radiation...........,...,..,..........91 4.8Summ8y..........................................92 5.PROCESSING OF ADVANCED THERMOPLASTIC COMPOSITES.···············.96 5.1 Introduction.…9G 5.2 Advantages/Disadvantages................ 5.3 Treatment of Fibers......,,,.·,...······ 5.4 Combination of Fibers with Matrix..,..,.······· ····.98 5.4.1 Hot Melt Coating.,.·.··············· 5.4.2 Solution Processing ..... 5.4.3 ln-Situ Polymerization of Monomers or Prepolymers.,··...···,. .,.101 5.4.4 Film Stacking......·.·. ,..101 5.4.5 Powder Coating.,············ ··.102 5.4.6 Fiber Hybridization,,.············ ,·.102 5,5Ly-Up,。,.。,,,.。.。,.,,,,,。.,,,,,,.。。.,。. ...108 5.6 Processing Techniques for Thermoplastic Composites.,··,·,,····, .,.108 5.6.1 Melting.,.,······ ..108 5.6.2 Consolidation,,··········· ,·.108 5.6.3 Solidification.············· ·.110 5.6.4 Residual Stresses,··············· ..110 5.6.5 Models.. .111 5.7 Processing of Flat Thermoplastic Laminates..... ..111 5.7.1 Compression Molding,,,,,,,.,··,. ,.112 5.7.2 Autoclave Technology ........ ,112 5.7.3 Automated Lamination and Consolidation.... .112 5.8 Forming Techniques.,.,,.····..··.······ ..113 5.8.1 Matched Die Press Forming...... .114 5.8.2 Rubber Pad Press Forming ... 114 5.8.3 Diaphragm Forming....... ..117 5.8.4 Hydroforming.,,,····· 117 5.8.5 Autoclave/Vacuum Forming .... ···.117 58.6 Filament Winding.·,,.,.·..,, ....120 5.8.7 Pultrusion.·.············· ...120 5.8.8 Roll Forming..··,········· ·.,121viii Contents and Subject Index 3.MORPHOLOGY...................................................53 3.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . ,. . . . . . . . . . . . . . . . . . . . . . .53 3.2 Factors Influencing Morphology of Semi-Crystalline Thermoplastics. . . . . . . . . . . . . .53 3.2.1 Processing Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 3.2.2 Foreign Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 3.3 Morphology-Property Relationships of Semi-Crystalline Thermoplastics. . . . . . . . . . . .60 3.4 Summary.....................................................64 4. PERFORMANCE OF THERMOPLASTIC BASED COMPOSITES . . . . . . . . . . . . . . . . . .67 4.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 4.2 Room Temperature Mechanical Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 4.3 Elevated Temperature Mechanical Properties . . . . . . . . . . . . . . . . . . . . . . , . . . , . .75 4.4 Damage Resistance and Tolerance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 4.4.1 lnterlaminar Fracture Toughness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _ .78 4.4.2 Delamination Behavior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 4.4.3 Damage Tolerance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83 4.5 Fatigue Resistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86 4.6 Time-Dependent Behavior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89 4.7 Resistance to Thermal Cycling and Ionizing Radiation . . . . . . . . . . . . . . . . . . . . . . .91 4.7.1 Thermal Cycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91 4.7.2 Electron Radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91 4.8 Summary.....................................................92 5. PROCESSING OF ADVANCED THERMOPLASTIC COMPOSITES. . . . . . . . . . . . . . . . .96 5.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96 5.2 Advantages/Disadvantages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96 5.3 Treatment of Fibers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97 5.4 Combination of Fibers with Matrix. . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . .98 5.4.1 Hot Melt Coating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 5.4.2 Solution Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 5.4.3 In-Situ Polymerization of Monomers or Prepolymers . . . . . . . . . . . . . . . . . . 101 5.4.4 Film Stacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I01 5.4.5 Powder Coating.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 5.4.6 Fiber Hybridization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I02 5.5 Lay_Up.....................................................lO8 5.6 Processing Techniques for Thermoplastic Composites. . . . . . . . . . . . . . . . . . . . . . . 108 5.6.1 Melting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I08 5.6.2 Consolidation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108 5.6.3 Solidification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 5.6.4 Residual Stresses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 5.6.5 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..lll 5.7 Processing of Flat Thermoplastic Laminates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 5.7.1 Compression Molding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 5.7.2 Autoclave Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 5.7.3 Automated Lamination and Consolidation. . . . . . . . . . . . . . . . . . . . . . . . . 112 5.8 Forming Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113 5.8.1 Matched Die Press Forming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 5.8.2 Rubber Pad Press Forming . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 5.8.3 Diaphragm Forming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I17 5.8.4 Hydroforming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I17 5.8.5 Autoclave/Vacuum Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 5.8.6 Filament Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I20 5.8.7 Pultrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I20 5.8.8 Roll Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I21