Manufacturing Optimization and Experimental Investigation of Ex-situ Core-shell Particles Toughened Carbon/Elium® Thermoplastic Composites

Current research investigates the effect of the core-shell (C/SH) particles in composites manufactured using novel thermoplastic Elium® resin and carbon fiber reinforcement of different areal weights, 200 gsm and 400 gsm bi-angle non-crimp carbon fabrics (NCCFs). The core-shell particles were activated using the ex-situ methodology which involves the activation of particles before the Resin transfer molding (RTM) injection process. Recommended particle activation parameters are established after carrying out a detailed microscopic study to understand the melting and flattening behavior of these particles. Static indentation and damping attributes are studied to understand the influence of C/SH particles added novel carbon/Elium® composite in improving the out-of plane properties and dynamic mechanical attributes respectively. The interply regions were also toughened with the addition of 1% core-shell particles and the intensity of load drop has reduced by 20% while comparing the thick and thin ply NCCF/Elium® composites. Microscopic examination has shown that the core-shell particles helped to spread the damage evenly throughout the specimen and absorbed more energy during the static-indentation. Loss factor or damping for thick ply Elium® composite and thin ply epoxy composite is increased by 19% and 16.4% with the addition of 5% and 1% C/SH particles respectively. The underlying reasons for improvement offered by C/SH particles in quasi-static impact and dynamic mechanical tests are also deliberated in this paper.