Influence of materials processing on impact properties of compression-moulded commingled thermoplastic composites

The impact properties of commingled E-glass-polypropylene composites with varying fibre architectures have been investigated. The fabric structures include balanced and unbalanced twill weaves and a three-dimensional woven fabric. Comparative data for glass mat thermoplastics are included and additional comparisons with crossply continuous filament tape laminates are also made. All the materials were processed into flat panels via non-isothermal compression moulding. First, voidage was correlated with processing parameters to produce well consolidated laminates. Mechanical tests included tensile, flexural, and interlaminar shear. Impact tests include Charpy and falling weight; the latter ranged from 15 J to full penetration and were followed by IR thermography and microscopy to determine the extent of damage areas. The results demonstrate the evolution of damage with increasing impact energies and the mode of impact damage propagation for the different fibre architectures.