Random Glass Mat Thermoplastic (GMT) composites are increasingly being used by the automotive industry for manufacturing semi-structural components. The polypropylene based materials are characterized by superior strength, impact resistance and toughness. Since polymers and their composites are inherently viscoelastic, i.e. their mechanical properties are dependent on time and temperature. They creep under constant mechanical loading and the creep rate is accelerated at elevated temperatures. In typical automotive operating conditions, the temperature of the polymer composite part can reach as high as 80°C. Currently, the only known report in the open literature on the creep response of commercially available GMT materials offers data for up to 24 MPa at room temperature. In order to design and use these materials confidently, it is necessary to quantify the creep behaviour of GMT for the range of stresses and temperatures expected in service. The primary objective of this proposed research is to characterize and model the creep behaviour of the GMT composites under thermo-mechanical loads. In addition, tensile testing has been performed to study the variability in mechanical properties. The thermo-physical properties of the polypropylene matrix including crystallinity level, transitions and the variation of the stiffness with temperature have also been determined. In this work, the creep of a long fibre GMT composite has been investigated for a relatively wide range of stresses from 5 to 80 MPa and temperatures from 25 to 90°C. The higher limit for stress is approximately 90% of the nominal tensile strength of the material. A Design of Experiments (ANOVA) statistical method was applied to determine the effects of stress and temperature in the random mat material which is known for wild experimental scatter. Two sets of creep tests were conducted. First, preliminary short-term creep tests consisting of 30 minutes creep followed by recovery were carried out over a wide range of stresses and temperatures. These tests were carried out to determine the linear viscoelastic region of the material. From these tests, the material was found to be linear viscoelastic up-to 20 MPa at room temperature and considerable non-linearities were observed with both stress and temperature. Using Time-Temperature superposition (TTS) a long term master curve for creep compliance for up-to 185 years at room temperature has been obtained. Further, viscoplastic strains were developed in these tests indicating the need for a non-linear viscoelastic viscoplastic constitutive model. The second set of creep tests was performed to develop a general non-linear viscoelastic viscoplastic constitutive model. Long term creep-recovery tests consisting of 1 day creep followed by recovery has been conducted over the stress range between 20 and 70 MPa at four temperatures: 25°C, 40°C, 60°C and 80°C. Findley’s model, which is the reduced form of the Schapery non-linear viscoelastic model, was found to be sufficient to model the viscoelastic behaviour. The viscoplastic strains were modeled using the Zapas and Crissman viscoplastic model. A parameter estimation method which isolates the viscoelastic component from the viscoplastic part of the non-linear model has been developed. The non-linear parameters in the Findley’s non-linear viscoelastic model have been found to be dependent on both stress and temperature and have been modeled as a product of functions of stress and temperature. The viscoplastic behaviour for temperatures up to 40°C was similar indicating similar damage mechanisms. Moreover, the development of viscoplastic strains at 20 and 30 MPa were similar over all the entire temperature range considered implying similar damage mechanisms. It is further recommended that the material should not be used at temperature greater than 60°C at stresses over 50 MPa. To further study the viscoplastic behaviour of continuous fibre glass mat thermoplastic composite at room temperature, multiple creep-recovery experiments of increasing durations between 1 and 24 hours have been conducted on a single specimen. The purpose of these tests was to experimentally and numerically decouple the viscoplastic strains from total creep response. This enabled the characterization of the evolution of viscoplastic strains as a function of time, stress and loading cycles and also to co-relate the development of viscoplastic strains with progression of failure mechanisms such as interfacial debonding and matrix cracking which were captured in-situ. A viscoplastic model developed from partial data analysis, as proposed by Nordin, had excellent agreement with experimental results for all stresses and times considered. Furthermore, the viscoplastic strain development is accelerated with increasing number of cycles at higher stress levels. These tests further validate the technique proposed for numerical separation of viscoplastic strains employed in obtaining the non-linear viscoelastic viscoplastic model parameters. These tests also indicate that the viscoelastic strains during creep are affected by the previous viscoplastic strain history. Finally, the developed comprehensive model has been verified with three test cases. In all cases, the model predictions agreed very well with experimental results.

Random Glass Mat Thermoplastic (GMT) composites are increasingly being used by the automotive industry for manufacturing semi-structural components. The polypropylene based materials are characterized by superior strength, impact resistance and toughness. Since polymers and their composites are inherently viscoelastic, i.e. their mechanical properties are dependent on time and temperature. They creep under constant mechanical loading and the creep rate is accelerated at elevated temperatures. In typical automotive operating conditions, the temperature of the polymer composite part can reach as high as 80°C. Currently, the only known report in the open literature on the creep response of commercially available GMT materials offers data for up to 24 MPa at room temperature. In order to design and use these materials confidently, it is necessary to quantify the creep behaviour of GMT for the range of stresses and temperatures expected in service. The primary objective of this proposed research is to characterize and model the creep behaviour of the GMT composites under thermo-mechanical loads. In addition, tensile testing has been performed to study the variability in mechanical properties. The thermo-physical properties of the polypropylene matrix including crystallinity level, transitions and the variation of the stiffness with temperature have also been determined. In this work, the creep of a long fibre GMT composite has been investigated for a relatively wide range of stresses from 5 to 80 MPa and temperatures from 25 to 90°C. The higher limit for stress is approximately 90% of the nominal tensile strength of the material. A Design of Experiments (ANOVA) statistical method was applied to determine the effects of stress and temperature in the random mat material which is known for wild experimental scatter. Two sets of creep tests were conducted. First, preliminary short-term creep tests consisting of 30 minutes creep followed by recovery were carried out over a wide range of stresses and temperatures. These tests were carried out to determine the linear viscoelastic region of the material. From these tests, the material was found to be linear viscoelastic up-to 20 MPa at room temperature and considerable non-linearities were observed with both stress and temperature. Using Time-Temperature superposition (TTS) a long term master curve for creep compliance for up-to 185 years at room temperature has been obtained. Further, viscoplastic strains were developed in these tests indicating the need for a non-linear viscoelastic viscoplastic constitutive model. The second set of creep tests was performed to develop a general non-linear viscoelastic viscoplastic constitutive model. Long term creep-recovery tests consisting of 1 day creep followed by recovery has been conducted over the stress range between 20 and 70 MPa at four temperatures: 25°C, 40°C, 60°C and 80°C. Findley’s model, which is the reduced form of the Schapery non-linear viscoelastic model, was found to be sufficient to model the viscoelastic behaviour. The viscoplastic strains were modeled using the Zapas and Crissman viscoplastic model. A parameter estimation method which isolates the viscoelastic component from the viscoplastic part of the non-linear model has been developed. The non-linear parameters in the Findley’s non-linear viscoelastic model have been found to be dependent on both stress and temperature and have been modeled as a product of functions of stress and temperature. The viscoplastic behaviour for temperatures up to 40°C was similar indicating similar damage mechanisms. Moreover, the development of viscoplastic strains at 20 and 30 MPa were similar over all the entire temperature range considered implying similar damage mechanisms. It is further recommended that the material should not be used at temperature greater than 60°C at stresses over 50 MPa. To further study the viscoplastic behaviour of continuous fibre glass mat thermoplastic composite at room temperature, multiple creep-recovery experiments of increasing durations between 1 and 24 hours have been conducted on a single specimen. The purpose of these tests was to experimentally and numerically decouple the viscoplastic strains from total creep response. This enabled the characterization of the evolution of viscoplastic strains as a function of time, stress and loading cycles and also to co-relate the development of viscoplastic strains with progression of failure mechanisms such as interfacial debonding and matrix cracking which were captured in-situ. A viscoplastic model developed from partial data analysis, as proposed by Nordin, had excellent agreement with experimental results for all stresses and times considered. Furthermore, the viscoplastic strain development is accelerated with increasing number of cycles at higher stress levels. These tests further validate the technique proposed for numerical separation of viscoplastic strains employed in obtaining the non-linear viscoelastic viscoplastic model parameters. These tests also indicate that the viscoelastic strains during creep are affected by the previous viscoplastic strain history. Finally, the developed comprehensive model has been verified with three test cases. In all cases, the model predictions agreed very well with experimental results.

The current research is part of a wider experimental program on creep modeling of glass mat reinforced polypropylene composites which are increasingly being used in molding automotive parts. This specific study is focused on the dimensional and thermal stability of chopped fibre mat and long fibre mat composites. The objective of the study is two-fold. First, to characterize in-situ the micro-failure mechanisms associated with damage accumulation during creep at room temperature and at service temperature (80°C) for stresses up to 67% of the ultimate tensile strength. Second, to characterize the effects of prolonged exposure at elevated temperature on the crystallinity and chemical degradation of the polypropylene matrix. In the first part of the investigation, micro-failure mechanisms including fibre-matrix interface, matrix yielding and cracking during the creep process have been captured in-situ using reflection microscopy. Specimens with 12 mm gauge length were mounted onto a Minimat tensile tester. The applied stress levels of interest were 33% and 67% of the ultimate tensile strength (UTS) at room temperature (RT) and high temperature (HT), respectively. It was found that the deformation mechanisms do not change with temperature but creep in the chopped fibre material is substantially higher than that in the long-fibre. Creep deformation is typically associated with multiple transverse crack initiation at the fibre-matrix interface, crack crazing and rapid coalescence of the small cracks leading to abrupt fracture. Debonding of the fibres is usually detected at the loading stage of the test but fibre breakage is minimal even at high temperature. The change in creep strain at room temperature is similar for both composites but creep strains are highly sensitive to the fibre-mat type at higher temperature. Long-fibre mat structures offer greater creep resistance. Micro-indentations on the matrix-rich regions showed elongation along the loading direction but shear yielding (distortion of indentations) was not noticeable. Using scanning electron microscopy (SEM), the fibre pullout was observed to be pronounced thus suggesting poor adhesion at the fibre-matrix interface. In the second part of this study, the effects of elevated temperature aging on the microstructural changes of isotactic polypropylene matrix in a composite have been studied using wide-angle X-ray scattering (WAXS) and Fourier-transform infrared spectroscopy (FTIR). The objective was to quantify small and slow changes in crystallinity due to thermal aging. To minimize sample variability, polypropylene resin was extracted from the molded composite plaque. Changes in crystallinity level and crystalline form were detected using WAXS after prolonged aging at 90 and 140 °C. FTIR was utilized to monitor in-situ crystallinity changes and to detect oxidation products due to thermal decomposition. The level of crystallinity was monitored by changes in the absorbance ratio of A997/A973 and A841/A973; the former ratio was found to be more sensitive for detecting crystallinity changes. Aging at 140°C resulted in oxidation. The kinetics of secondary crystallization for the aging conditions studied was characterized using Avrami plots.

The current research is part of a wider experimental program on creep modeling of glass mat reinforced polypropylene composites which are increasingly being used in molding automotive parts. This specific study is focused on the dimensional and thermal stability of chopped fibre mat and long fibre mat composites. The objective of the study is two-fold. First, to characterize in-situ the micro-failure mechanisms associated with damage accumulation during creep at room temperature and at service temperature (80°C) for stresses up to 67% of the ultimate tensile strength. Second, to characterize the effects of prolonged exposure at elevated temperature on the crystallinity and chemical degradation of the polypropylene matrix. In the first part of the investigation, micro-failure mechanisms including fibre-matrix interface, matrix yielding and cracking during the creep process have been captured in-situ using reflection microscopy. Specimens with 12 mm gauge length were mounted onto a Minimat tensile tester. The applied stress levels of interest were 33% and 67% of the ultimate tensile strength (UTS) at room temperature (RT) and high temperature (HT), respectively. It was found that the deformation mechanisms do not change with temperature but creep in the chopped fibre material is substantially higher than that in the long-fibre. Creep deformation is typically associated with multiple transverse crack initiation at the fibre-matrix interface, crack crazing and rapid coalescence of the small cracks leading to abrupt fracture. Debonding of the fibres is usually detected at the loading stage of the test but fibre breakage is minimal even at high temperature. The change in creep strain at room temperature is similar for both composites but creep strains are highly sensitive to the fibre-mat type at higher temperature. Long-fibre mat structures offer greater creep resistance. Micro-indentations on the matrix-rich regions showed elongation along the loading direction but shear yielding (distortion of indentations) was not noticeable. Using scanning electron microscopy (SEM), the fibre pullout was observed to be pronounced thus suggesting poor adhesion at the fibre-matrix interface. In the second part of this study, the effects of elevated temperature aging on the microstructural changes of isotactic polypropylene matrix in a composite have been studied using wide-angle X-ray scattering (WAXS) and Fourier-transform infrared spectroscopy (FTIR). The objective was to quantify small and slow changes in crystallinity due to thermal aging. To minimize sample variability, polypropylene resin was extracted from the molded composite plaque. Changes in crystallinity level and crystalline form were detected using WAXS after prolonged aging at 90 and 140 °C. FTIR was utilized to monitor in-situ crystallinity changes and to detect oxidation products due to thermal decomposition. The level of crystallinity was monitored by changes in the absorbance ratio of A997/A973 and A841/A973; the former ratio was found to be more sensitive for detecting crystallinity changes. Aging at 140°C resulted in oxidation. The kinetics of secondary crystallization for the aging conditions studied was characterized using Avrami plots.