Reactive extrusion of frontally polymerizing continuous carbon fiber reinforced polymer composites

Nadim S. Hmeidat, Michael Zakoworotny, Yun Seong Kim, Thien B. Le, Gavin DeBrun, Rohan Shah, Jacob J. Lessard, Jeffery S. Moore, Jeffery W. Baur, Philippe H. Geubelle, Nancy R. Sottos, Sameh H. Tawfick

Research output: Contribution to journalArticlepeer-review

Abstract

The manufacturing of carbon fiber-reinforced polymer (CFRP) composites demands rapid and energy-efficient strategies. Frontal polymerization (FP) enables the manufacturing of CFRP using dicyclopentadiene (DCPD) thermoset polymer which meets these requirements. In this work, we introduce reactive extrusion of CFRP (RE-CFRP), where two rollers provide localized heat and pressure to sustain the curing reaction and the consolidation of a continuous carbon fiber tow pre-impregnated with DCPD. We study the effect of the extrusion speed, temperature, and compaction force on the properties of the produced CFRP. Mechanical testing confirms that the resulting fiber volume fraction and the elastic modulus are similar to bulk cured tows. A homogenized thermo-chemical model is developed to study the effect of the process parameters on the polymerization reaction. The process produces hollow woven composite tubes directly via extrusion and in situ curing. Overall, this process offers advantages in curing, tooling, speed, and energy.

Original languageEnglish (US)
Article number108609
JournalComposites Part A: Applied Science and Manufacturing
Volume190
DOIs
StatePublished - Mar 2025

Keywords

  • Additive manufacturing
  • Continuous fiber composites
  • Dicyclopentadiene
  • Frontal polymerization
  • Homogenized thermo-chemical model
  • Reactive extrusion
  • Thermoset

ASJC Scopus subject areas

  • Ceramics and Composites
  • Mechanics of Materials

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