Process Factors in Long-Fiber Thermoplastic Compression Molding Materials

Long-fiber thermoplastic (LFT) materials are a versatile category of composite materials that can be directly compounded (LFT-D) in twin screw extruders and compression molded. Originating in the automotive sector, the LFT-D process is becoming increasingly attractive for other industries where low cycle times, lightweight performance and recyclability are required. The purpose of this work is to summarize mechanical properties and findings from the investigations into LFT-D process–microstructure–property relationships and present a design of experiments (DoE) study based on the current state of the art. Primary parameters from LFT-D compounding, screw speed, fiber roving amount and polymer throughput mp are chosen as DoE factors. Polyamide 6 (PA6) is reinforced with a glass fiber (GF) mass fraction wf between wf = 20% and wf = 60%. Tensile, flexural and impact properties are chosen as DoE output parameters, characterized and discussed in relation to the state of the art. The unique microstructure of LFT-D materials, especially the existence of a charge and flow area as well as the fiber migration, is considered in the discussion. All mechanical properties characterized have a linear relation to wf. This study demonstrates the interactive relationship between the main factors and wf, which significantly influences the mechanical properties. This dependence of wf on the DoE factors is accounted for in advanced response contour plots proposed in this work. Parameter recommendations for the screw speed are reported by ranges of wf and polymer throughput for the goal of maximum mechanical properties or low coefficient of variations. At wf < 30% a low screw speed is recommended to improve most mechanical properties as well as the coefficient of variation.