Processing of fibre reinforced thermoplastic composites

With the advent of high performance thermoplastic polymers, structural applications for thermoplastic composites are increasing rapidly. Thermoplastic matrix composites possess distinct advantages vis-a-vis thermoset matrix composites in terms of recyclability, high specific strength and specific stiffness, corrosion resistance, enhanced impact toughness, cost effectiveness, and flexibility of design. Since 1990s, the number of material forms and combinations in fibre reinforced thermoplastic polymers has increased exponentially, thereby expanding application avenues in transportation, automotive, mass transit, marine, aerospace, military and construction sectors. In this paper we review the state of the art in processing of fibre reinforced thermoplastics. We start with a brief description of thermoplastic polymers used in structural applications followed by material forms and methods of impregnation of the reinforcement with polymer. Long fibre based processing methods are described next. A description of emerging thermoplastic composite processes and products follows. Finally we review process models and representative applications.