Journal
COMPOSITES PART A-APPLIED SCIENCE AND MANUFACTURING
Volume 39, Issue 5, Pages 796-804Publisher
ELSEVIER SCI LTD
DOI: 10.1016/j.compositesa.2008.01.016
Keywords
carbon fibers; polymer matrix composites; mechanical properties; consolidation; total hip prosthesis
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The fabrication process for a novel carbon fiber-reinforced polymer (polyamide 12) composite femoral stem using inflatable bladder molding was studied. Effect of processing temperature, holding time and applied internal pressure on the consolidation quality of the composite was investigated. Consolidation quality was evaluated by density and void content measurements and scanning electron microscope analysis. As expected, void content (porosities) and presence of large resin pockets were found to increase for lower processing temperature, holding time and applied pressure. Crystallinity as well as melting temperatures measured using differential scanning calorimetry could be related to molding conditions. A progressive reduction of the previous thermal history (crystalline peak of neat composite) and an increase in crystallinity were obtained for higher molding temperature. Static compression testing with void content analysis of molded specimens was used to determine optimal molding conditions. The composite structure molded showed compressive modulus close to cortical bone's. Compression load at failure of composites molded in optimal conditions were found to be three times higher than those of femoral bone for jumping on one leg or 10 times those for normal gait. The molded composite structure appears to be an excellent candidate for femoral stems used in total hip arthroplasty. (C) 2008 Elsevier Ltd. All rights reserved.
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