pps proceeding - Abstract Preview
pps proceeding
Symposium: S10 - Injection Molding
Oral Presentation
 
 

Process evaluation of foam injection molding with chemical and physical blowing agents for fiber reinforced thermoplastics

Roch Alexander (1)*, Huber Timo (2), Kehret Lara (2), Potyra Tobias (3), Henning Frank (4), Elsner Peter (5)

(1) Fraunhofer Institute for Chemical Technology - Pfinztal - Germany, (2) Fraunhofer Institute for Chemical Technology ICT - Pfinztal - Germany, (3) Fraunhofer Project Centre for Composite Research at Western University - Ontario - Canada, (4) Fraunhofer Institute for Chemical Technology ICT, Karlsruhe Institute of Technology KIT - Karlsruhe - Germany, (5) Fraunhofer Institute for Chemical Technology ICT, Karlsruhe Institute of Technology KIT - Karlsruhe - Germany

Components made from fiber-reinforced thermoplastics show good weight specific mechanical properties and can be manufactured in a cost efficient way using injection molding. By combining this material group with foam injection molding (FIM) the lightweight potential can be further improved. The result is a single material system with a sandwich-like structure: fiber-reinforced foamed core and compact skin layers. Different FIM processes are available on the market. Chemical blowing agents (CBA) in combination with a standard injection molding set-up and the use of physical blowing agents (PBA) with the MuCellŪ technology are common. CBAs are admixed to the polymer and split of gases above certain process temperatures. PBAs are introduced directly into the melt. Using these processes glass-fiber-reinforced polyamide 6 (PA6) foams were manufactured with a constant weight per unit area and varying density reductions. Precision mold opening (breathing mold technology) was selected for the foaming process. This technology allows higher density reductions and a definite adjustment. The injection compression mold is opened after injection, enlarging the cavity to its final volume and causing a pressure drop which initiates the foaming process. The average fiber length has a significant influence on the mechanical properties. Especially the energy absorption capacity (impact strength) of fiber-reinforced foam components correlate with the fiber length. This means that for processing the objective must be to preserve the fibers during the plastification and injection. Investigations into different semi-finished granulates have been carried out using different screw designs: standard three-section screw design and fiber-preserving screw geometry at the mixing zone. The focus of this study is FIM of glass-fiber-reinforced PA6 using CBAs and PBAs. Experiments show the influence of density reduction, material and processing on the mechanical properties and the foam structure.