Fiber–fiber interactions in carbon mat thermoplastics

Carbon mat thermoplastics (CMT) consisting of 12.7 mm long, chopped carbon fibers in a polypropylene matrix were manufactured using the wetlay technique at fiber volume fractions (FVF) from 10% to 25%, and tests simulating the compression molding process were conducted. The packing stress of the CMT followed a power law relation with FVF. A single fiber pull-out fixture was used to measure the frictional and hydrodynamic lubrication coefficients at fiber–fiber touch points, and results were fit with an existing relation for glass mat thermoplastics. In isothermal squeeze flow the load–displacement behavior for the 10% FVF CMT was similar in shape to that for a fluid with a yield stress. However, for FVFs of 15–25%, the load–displacement curves showed a load spike at the beginning of the flow, then followed the curve for a fluid with a yield stress. The spike was attributed to fiber breakage that increased with increasing FVF of the sample.