The National Science Foundation State of Michigan/Industry University Cooperative Research Center on Low-Cost, High-Speed Polymer Composites Processing was established at Michigan State University on September 1, 1991. Financial commitments by the State of Michigan and Industry through the National Consortium for manufacturing Sciences (NCMS), have been made to support the Center research at approximately $1,000,000 per year. The development of applications in polymer composites has been driven primarily by the performance requirements of aerospace and military applications. Thus, the prevailing practice regarding polymer composites processing has typically not been cost driven and is characterized by the utilization of expensive constituents and slow manual processing techniques. Major scientific and technological barriers must be solved to make the transition into widespread use of high technology composite materials in the durable goods industry. The focus of the Center, developed as a result of considerable interaction with industry, is to address the scientific and technological issues to reduce cost, increase processing speed and to reduce the design-to-manufacture cycle time.

Core Research Program

The  industrial sponsors of the Center have identified the critical technological barriers preventing polymer matrix composites from achieving their potential in the durable goods fields. Five technical thrusts were identified. The critical issues that are the basis for these thrusts and are related to reductions in cost and time for design and processing of polymer composites are: (1) novel processing; (2) flow of resin into complex fiber preforms; (3) use of recycled/renewable low-cost materials; (4) intelligent modeling of processes for design and manufacturing; and (5) interphases and joining. These technical thrusts provide the continuing focus for the Center's core research plan directed toward the goal of Low-Cost, High-Speed Polymer Composites Processing. The Core research is program is supported by the National Science Foundation, State of Michigan and Industrial membership money.

Non-Core or Applied Research

Core research provides the basic understanding upon which new ideas and innovations are developed, leading to new technology and patents. The transition of core research into applications is facilitated by the support of "non-core" research projects, some of which result in patentable technology. In addition to the Core research program, industrial members can sponsor individual or joint, exclusive and even proprietary projects to exploit the results of the Core research projects.

Research Thrusts

Currently twenty-four projects under five continuing research thrusts have been selected and approved by the Industrial Advisory Board for the Center's research program. Eighteen projects have already been completed at the Center. The projects at the Center are currently being conducted by collaborating investigators at Michigan State University (MSU), University of Michigan (UM), and Wayne State University (WSU). Researchers from the Michigan Molecular Institute (MMI), Michigan Technological University (MTU), University of Detroit Mercy (UDM), and Western Michigan University (WMU) are also conducting research through NCMS, and have been involved with Center projects in the past.

1. Novel Processing
   The Novel Processing thrust is charged with developing additional technologies that have the potential for achieving cost effective processing of polymer composites. In the current design of the Center, five project areas have been identified for this thrust: 1) Microwave Processing of Polymer Composites, 2) Aligned Discontinuous Fiber Preforms 3) Rapid Photopolymerization for Liquid Molding, 4) Reliability and Durability of Coated Composite Panels and 5) Microwave Pultrusion Processing.
    
   Left: Microwave chamber
   Right: A researcher conducts measurements on the effect of microwave processing on polymer composite properties
    
2. Liquid Molding
   The Liquid Molding thrust has considerable promise as a technology for achieving cost effective processing of polymer composites for structural durable goods applications. The overall goal of this thrust is to decrease processing times and maintain overall part quality and performance by elimination of resin rich areas or insufficient fiber wetting. This thrust addresses engineering issues in the following processing technologies: injection of thermosets into a mold containing a fiber preform; injection of thermosets containing chopped fibers into a mold; and injection of thermoplastic melts containing discontinuous chopped fibers into a mold. Five different critical areas have been identified in this thrust.
   
   
   Above: Liquid molding process
    
3. Renewable/Recyclable Materials
   The Renewable/Recyclable Materials Thrust focuses on component cost reduction by making use of renewable and recyclable materials. The emphasis of this thrust is to produce value added products from low-cost composites derived from low cost constituents. Cellulosic fibers offer a low cost alternative to glass fibers in chopped fiber composites. The matrices targeted as having the most potential are to be prepared by blending/alloying of reclaimed/recycled polymers (recycled PET, PE) or natural polymers (lignocellulosics, amylose) with thermoplastics (PP, SMA, PE) using reactive extrusion and sulfonation. The use of reclaimed/recycled polymers not only results in lowering the cost of the composite but opens up high value markets for the use of recycled polymer resins. The use of lignocellulosics as a blend component of the thermoplastic matrix is expected to provide resistance to creep and offer other additional advantages including lowering the cost of the composite. The use of recycled or natural polymers as mere fillers or extenders in the thermoplastic matrix is not intended. What is envisioned is the creation of new thermoplastic alloy systems with enhanced functionality and properties in a two-phase morphology which will give rise to enhanced and improved composite matrix properties. The thrust will also explore the use of biodegradable polymers as the basis of composite materials. Finally, the thrust will develop important life-cycle analysis methodologies to insure that during design the appropriate materials, processes and disposal methods are employed for environmentally friendly manufacturing.
    
4. Advanced Computational Techniques in Processing
   The Advanced Computing Thrust (ACT) impacts aspects of all the other Thrusts in the Center. This effort is lead by the Intelligent Systems Laboratory at MSU. The goals of the Thrust are to (a) develop computer frameworks for storing current industrial and theoretical knowledge of polymer composites design and manufacturing; (b) to develop a software infrastructure capable of supporting knowledge sharing, particularly tutorial-based training, and eventually supporting electronic commerce; (c) to apply off-the-shelf tools and techniques of modern computer science to problems in composites design and manufacturing; and (d) support the development of new computing techniques for composites activities. Over the life of the Center, as developments that expand the knowledge of design and processing are made in all Center Thrusts, these developments will be made available to the industrial composites community in part via the ACT.
    

   

   Above: Knowledge-based systems are used to analyze a
   composite processing, sensing and control facility

    

5. Interphases and Joining
   The final thrust is the Interphases and Joining Thrust. Like the Advanced Computing Thrust, the Interphases and Joining thrust impacts aspects of all other thrusts of the Center. Adhesion has a central role in composites both at the micro-scale and the macro-scale. Fiber matrix adhesion determines the overall performance of a composite part and how the loadings are transferred from the matrix to the fiber. In larger scale structures, composite parts must be bonded or joined to other composite parts and/or metal parts. If an adhesive is used to bond the parts then adhesion is again central to the performance of the entire structure. This region between the fiber matrix or the adhesive-adherend is called the interphase and is key to the initial and long-term durability and mechanical performance of the part or structure. Unlike the individual processing thrusts, the Interphases and Joining thrust touches all aspects of composite processing and parts. There are three critical areas to this thrust.

Current Research

Click on a thrust to view abstracts & projects:

1. Novel Processing
2. Liquid Molding
3. Renewable / Recyclable Materials
4. Advanced Computational Techniques in Processing
5. Interphases and Joining

Technology Transfer Activities

Click here to access the Office of Technology Transfer's Current Projects.
 

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