Co-Bonded Hybrid Thermoplastic-Thermoset Composite Interphase: Process-Microstructure-Property Correlation.

Area of Science:

• Materials Science and Engineering
• Polymer Science
• Composite Materials

Background:

• Co-bonding joins prefabricated parts with thermoset resins during curing, crucial for fiber-reinforced composites.
• Manufacturing hybrid composites via co-bonding presents challenges due to interdiffusion complexities between thermoset and thermoplastic polymers at the interface.

Purpose of the Study:

• To investigate the interphase properties of co-bonded acrylonitrile butadiene styrene (ABS) thermoplastic to unsaturated polyester (UP) thermoset.
• To understand the effect of processing temperature on cure kinetics, interdiffusion kinetics, and resulting interphase characteristics.

Main Methods:

• Experimental study of co-bonded ABS/UP interfaces under varying processing temperatures.
• Analysis of cure and interdiffusion kinetics, interphase thickness, and microstructure.
• Development of models to predict interphase properties and estimation of temperature-dependent diffusivities using an inverse diffusion model.
• Mechanical characterization using Vickers microhardness testing.

Main Results:

• Processing temperature significantly influences the interdiffusion process between ABS and UP.
• Interphase thickness, microstructure, and mechanical performance are directly correlated with processing temperature and chemo-rheological properties.
• Vickers microhardness tests revealed a strong link between processing conditions, microstructure, and the mechanical response of the interphase.

Conclusions:

• Processing temperature is a critical parameter controlling the interdiffusion and interphase formation in co-bonded ABS/UP hybrid composites.
• Optimizing processing temperature is essential for tailoring interphase properties and enhancing the overall performance of these advanced materials.