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Injection molding of long fiber-reinforced thermoplastics is a well-established method in automotive industry to produce high quality structural parts in mass production without the need of further finishing, where the performance is strongly dependent on the fiber length. It is known that the processing parameters have to be carefully chosen as they directly influence the final fiber length and can therefore have a negative effect on the resulting mechanical properties of the part. Particularly in terms of impact behavior, the fiber length is seen as a key factor. The aim of the present work is to quantify the effects of the injection molding parameters on the impact behavior of long fiber reinforced compounds. In a first step the resulting fiber length of injection molded glass fiber reinforced polypropylene is analyzed as a function of the injection velocity, holding pressure, revolution speed and back pressure. The single steps of fiber length analysis are carefully investigated in terms of feasibility and accuracy, in order to assure that a reproducible and reliable test method is employed. Subsequently, the impact behavior of the PP-GF compounds is quantified by falling dart experiments, and the results are then correlated to the fiber length and the processing parameters to establish a fundamental processing-structure-property relationship. The investigation of the fiber length analysis shows that a high pyrolysis temperature leads to embrittlement of the glass fibers and a decrease of tensile strength of the single fibers. This may consequently lead to incorrect characterization of the fiber length due to fiber breakage. The results of the statistical investigation of the processing parameters indicate a significant influence of the back pressure on both impact energy and fiber length.

Influence of Processing Parameters on the Fiber Length and Impact Properties of Injection Molded Long Glass Fiber Reinforced Polypropylene