Pultrusion of large thermoplastic composite profiles up to φ 40 mm from glass-fibre/PET commingled yarns

Pultrusion is a rapid and cost-effective manufacturing technology for continuous fibre reinforced thermoplastic composite profiles. As the cross-sections of pultruded profiles grow to meet increasing performance requirements, manufacturing challenges concerning heat transfer are encountered. In this study, a two-dimensional finite element model was used to simulate the heat transfer and fluid flow physics of the pultrusion process for increasing diameters from 0 5-0 40 mm. To facilitate the experimental validation, a novel batch-wise pultrusion concept is introduced in which the impregnation process is observed in-situ using a transparent die. The pultrusion studies, conducted on glass-fibre/amorphous polyethylene terephthalate (GF/PET) commingled yarns, show that - with proper design - pultrusion is able to deliver consistent, high quality (void content < 2%) profiles up to at least 0 40 mm.

Automated summary

Pultrusion is a rapid and cost-effective manufacturing technology for continuous fiber reinforced thermoplastic composite profiles. This study focuses on simulating the heat transfer and fluid flow physics of the pultrusion process and demonstrates that, with proper design, consistent, high quality profiles can be achieved.