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The paper addresses the buckling of fibrous reinforcements which occurs due to motion of the amorphous matrix material during solidification. The motion of the matrix material is caused by a variation in cooling rate in different portions of a composite while the sample is cooling. In the course of this study, samples were prepared with a fiber reinforcement sandwiched between premolded sheets of polycarbonate. Samples were either processed in a two-cavity, “dogbone” shape mold or in a rectangular, single-cavity mold matched die compression mold. In order to visualize the motion of the molten matrix material, strands of polycarbonate blended with carbon black were mounted into the matrix. The buckling behavior demonstrated sensitivity, to the amount of reinforcement observed with single and multiple filaments of carbon and Kevlar and bundles of carbon fiber tows. This paper provides scaling considerations indicating the sensitivity of the observed effects to processing conditions and concludes with a discussion of the implications for load carrying capabilities of composites.

Breakage and Buckling of Fibrous Reinforcements During Fabrication of Thermoplastic Matrix Composites