Ultra-high-speed processing of nanomaterial-reinforced woven carbon fiber/polyamide 6 composites using reactive thermoplastic resin transfer molding

High-speed molding of continuous carbon fiber-reinforced composites was carried out by thermoplastic resin transfer molding using a very-low-viscosity thermoplastic monomer. After dispersing 0.1 wt.% of various nano-materials in e-caprolactam, a monomer of anionic polymerized polyamide 6 (A-PA6), the processing temperature and catalyst-activator contents were optimized based on the polymerization induction time required for resin injection in the mold. Additionally, the dispersion stability, solidification time, monomer conversion, crystallinity and mechanical properties of the composites were evaluated. Higher dispersion stability of the nanomaterials in A-PA6 resulted in a significantly shortened process cycle time on the order of seconds and higher crystallinity in the composite. In addition, carbon fibers treated with atmospheric plasma were used to increase the rate of resin impregnation into fibers. These factors not only increased composite fabrication productivity but also enhanced its mechanical properties