Mechanical properties of foamed long glass fiber reinforced polyphenylene sulfide integral sandwich structures manufactured by direct thermoplastic foam injection molding

Abstract To achieve high levels of lightweight design in automotive or aerospace industry, it is necessary to optimize certain composite material systems concerning their lightweight potential. With sandwich composites, which generally consist of a core which is coated with two face-layers, it is possible to reduce the overall part weight while increasing the specific mechanical properties under inhomogeneously distributed loads. Hereby the sandwich core ensures the load transmission while the face layers absorb the tensile and compressive loads occurring at bending stress. The aim is to increase the efficiency of said sandwiches while minimizing the weight per area by using for example (fiber-) reinforced face layers and foamed core materials. Polyphenylene sulfide (PPS) is an important high temperature, engineering thermoplastic polymer. Because of its properties it is used in the automotive, aerospace and electronics industry. As polyphenylene sulfide has a high processing temperature and requires processing know-how, there a few scientific studies on its foaming behavior. To understand the process-structure-property relationship of this material system, an experimental study on the foaming behavior of neat polyphenylene sulfide and long glass fiber reinforced polyphenylene sulfide using the high-pressure foam injection molding process is conducted. As it is also attractive from a manufacturing point of view to reduce the number of manufacturing steps and to operate with the source materials from the beginning of the process an in-line compounding and foam injection molding process is used. This allows the manufacturing of integral sandwich structures with connected, fiber reinforced face and foamed core layers in one shot via “direct thermoplastic foam injection molding”. With the findings of this study researchers and manufacturers of neat and fiber reinforced PPS parts are able to identify process parameter boundaries and the influence of these parameters on the sandwich structure and mechanical properties.