What’s PPS LCF10?

Composition

PPS LCF10 composite material is based on polyphenylene sulfide (PPS) and includes 10% long carbon fibers as a reinforcing filler, with the carbon fiber’s filling mass percentage reaching 20%. This composite material is noted for its excellent performance and wide range of applications.

The main component of PPS LCF10 is polyphenylene sulfide, a high-performance thermoplastic known for its outstanding heat resistance and chemical stability. The addition of long carbon fibers significantly enhances the material’s strength and rigidity. 

Performance Characteristics

1. High-Temperature Resistance: PPS LCF10 operates stably in environments up to 260°C, making it suitable for high-temperature conditions.
2. Excellent Mechanical Strength: The reinforced composite material exhibits superior tensile and flexural strength.
3. Lightweight: Compared to traditional metal materials, PPS LCF10 has a lower density, effectively reducing product weight.
4. Corrosion Resistance: The material offers good resistance to various chemicals, extending its service life.
5. Outstanding Wear Resistance: The addition of long carbon fibers provides excellent performance under friction and wear conditions.
6. Low Water Absorption: PPS LCF10 has a very low water absorption rate, making it suitable for use in humid environments.
7. Good Processability: The material is easy to process and mold, making it suitable for mass production.

Applications

PPS LCF10 is used in a wide range of high-tech industries, including aerospace, automotive, and electronic devices. In the aerospace sector, its high-temperature and corrosion resistance make it an ideal material for manufacturing critical components like turbine blades.

A Successful Application Case Share

PPS LCF10, developed and produced by Carbon Xiamen New Material, has been applied in the manufacture of turbine blades for aircraft engines. Traditional turbine blades often suffer from material fatigue in high-temperature environments, affecting overall engine performance. By using PPS LCF10, the component manufacturer successfully addressed this issue.

Experimental validation showed that turbine blades made from PPS LCF10 maintained excellent mechanical performance even at temperatures up to 800°C. The tensile strength increased by 25%, and weight was reduced by 15%. These improvements resulted in a 10% increase in engine efficiency and a 30% extension in maintenance intervals. This project not only enhanced engine reliability but also provided significant economic benefits to the aerospace industry.

How to Manufacture the Composites?

The impregnation method is commonly used by manufacturers to produce this material. Below is a detailed description of the impregnation process:

1. Material Preparation

– Matrix Material: Polyphenylene sulfide (PPS), a high-temperature and chemical-resistant thermoplastic.
– Reinforcement Material: Long carbon fibers, typically 10-30 mm in length, used to enhance the material’s strength and stiffness.

2. Fiber Pretreatment

Before impregnation, the long carbon fibers are usually pretreated to ensure good adhesion to the PPS matrix. This includes:

– Cleaning: Removing impurities and oils from the fiber surface.
– Surface Modification: Chemical treatment or plasma treatment to improve the fiber’s surface properties, enhancing bonding with the PPS matrix.

3. Matrix Material Preparation

PPS is typically in the form of pellets or powders, which need to be melted before processing. This step involves:

– Heating: Heating PPS to its melting temperature (typically 280-320°C) to turn it into a flowable molten state.
– Melting Mixing: In the molten state, PPS can be mixed uniformly using mixing devices (such as extruders).

4. Impregnation Process

– Impregnation: The pretreated long carbon fibers are immersed in the molten PPS. This process can be done through various methods, such as dipping, spraying, or rolling. The carbon fibers must be thoroughly wetted by the PPS to ensure complete coverage and penetration.

– Bubble Removal: During impregnation, bubbles may form, affecting the final material quality. Methods such as vacuum degassing or low-pressure treatment are used to remove bubbles and ensure good impregnation.

5. Cooling and Solidification

– Cooling: The impregnated fibers and PPS mixture needs to cool down to solidify the PPS from its molten state. This can be done through natural cooling or forced cooling (e.g., using cooling plates).

– Solidification: Ensure that the material is completely solidified during cooling to maintain its final physical properties and structural stability.

6. Post-Processing

– Cutting and Shaping: After solidification, the composite material can be cut and shaped as needed to meet the requirements of the final application.
– Inspection and Quality Control: The produced composite material undergoes various performance tests, such as tensile strength, flexural strength, and impact toughness, to ensure it meets design specifications and application requirements.

7. Application

– Application and Molding: The impregnated PPS LCF10 composite material can be used in various high-performance applications, such as automotive parts, electronic device housings, aerospace components, etc.

This impregnation process method’s advantage is its ability to uniformly disperse the reinforcement material (long carbon fibers) throughout the matrix material (PPS), significantly enhancing the composite material’s mechanical properties and thermal stability.

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