SAMPE Journal - September/October 2016 - 56

Feature Article
with PA, respectively. To refer to standard ASTM D 7137,
the ribs of the profile have been turned downwards and
pealed of in the area of an appropriate support. The
resulting damage to the profiles is shown in Figure 11.
On an uncoated profile, the impactor leaves a mark
and significant damage to the fibers is visible both on the
front side of the profile (impact side) and on the back side
(not shown). The profile coated with PE shows a dent
on the front side after impact and a clear delamination
of the thermoplastic top layer from the thermoset
composite core. Fiber breakage becomes apparent only
on the back side of the profile. The profile coated with
polyamide shows very little damage on the surface and
no delamination of the thermoplastic top layer. Fiber
breakage yet is apparent on the back side of the profile.
Conclusions and Outlook
The combination of pultrusion and extrusion offers
several process-wise and product-wise advantages. The
challenges for the combination of the two processes in
terms of different temperature, pressure and viscosity
developments have been analyzed in detail. Based on
the analysis, a special process layout and die technology
have been designed. A proof of concept has been given
and hybrid profiles have been produced, showing that
the process can be run using different types of materials.
Depending on the choice of material, a significant
improvement of the impact properties becomes
apparent.
In the future, the process will be investigated
further regarding process stability, speed and product
properties. The latter particularly encompasses the
investigation of the off-center position of the composite
profile in the top layer and the surface quality (waviness).
Special attention will also be paid to the joining quality for
polar thermoplastics such as PA and the issue of thermal
degradation of the PU matrix has to be investigated.
Acknowledgement
The research project "InPulSE" (18247N) of the
Forschungsvereinigung
Kunststoffverarbeitung
has been sponsored as part of the "Industrielle
Gemeinschaftsforschung und -entwicklung (IGF)" by the
German Bundesministerium für Wirtschaft und Technologie
(BMWi) due to an enactment of the German Bundestag
through the AiF. We would like to extend our thanks to all
organizations mentioned.

3. Laessig, R., Eisenhut, M., Mathias, A., Schulte, R.T.,
Peters, F., Kuehmann, T., Waldmann, T., Begemann, W.
Serienproduktion von hochfesten Faserverbundbauteilen. Roland
Berger Strategy Consultants, VDMA, 2012.
4. Prockat, J. FVK in Schienenfahrzeugen - Chancen und
Herausforderungen für funktionsintegrierte Ansätze. Umdruck
zum Wissenschaftstag am DLR Braunschweig.
Braunschweig, 2009.
5. Starr, T.F. Pultrusion for Engineers. Abington: Woodhead
Publishing Limited, 2000.
6. Profile Range. 5 Jan. 2016. Pultrex Ltd. 
7. The Pontresina Footbridge. 5 Jan. 2016. National
Composites
Network.

8. AVK-Preise: Zwei erste Plaetze für Hyundai Motor
Europe Technical Center und TU Muenchen. 5 Jan. 2016.
Lightweight
design.

9. Neitzel, M., Mitschang, P., Breuer, U. Handbuch
Verbundwerkstoffe. Muenchen, Wien: Carl Hanser Verlag,
2014.
10. Michaeli, W., Preuss, T. "Pultrusion of Composite
Profiles - Polyurethane (PU) as Alternative Matrix
System." Polymers & Polymer Composites 18 (2010) 9, pp. 537.
11. Conolly, M., King, J.; Shidaker, T., Duncan, A.
"Processing and Characterization of Pultruded
Polyurethane Composites." Proceedings of the 8th World
Pultrusion Conference (EPTA). Budapest, Ungarn, 2006.
12. Joshi, R.R., Cheolas, E.H., Cassidy, E.F., Karoly,
W.J., Coffee, H.D. "Polyurethane based Pultruded
Resins Improve the Environmental Image of Composite
Materials." Composites Convention and Trade Show. Tampa,
USA, 2001.
13. Passmann, D. "Polyurethane for Wind Turbine Rotor
Blades." JEC Composites Magazine (2013) 84, p. 48-50.
14. Sherman, L.M. "Polyurethane Composites: New
Alternative to Polyester and Vinyl Ester." Plastics Technology
60 (2006) 3, p. 60-73.
15. Chung, C.I.: Extrusion of Polymers - Theory and Practice.
Muenchen: Hanser Publishers, 2000.

References
1. Handbuch
Faserverbundkunststoffe.
AVK
-
Industrievereinigung
Verstärkte
Kunststoffe
e.V.
Wiesbaden:
Vieweg+Teubner/GWV
Fach-Verlage
GmbH, 2010.

16. Michaeli, W. Extrusionswerkzeuge für Kunststoffe und
Kautschuk. Muenchen, Wien: Carl Hanser Verlag, 2009.

2. Flemming,
M.,
Ziegmann,
G.,
Roth,
S.
Faserverbundbauweisen. Fertigungsverfahren mit duroplastischer
Matrix. Berlin, Heidelberg, New York: Springer Verlag,
1999.

18. N.N. Techn isches Merkblatt Elastocoat® C
6226/105. Datasheet by BASF Polyurethanes GmbH,
Lemfoerde, Germany, 2015.

56

17. Zipp, T. Fließverhalten beim 2-Komponenten-Spritzgießen.
RWTH Aachen, Ph.D. Thesis, 1992 - ISBN: 3-86073071-1.

SAMPE Journal, Volume 52, No. 5, September/October 2016

http://pultrex.com/profile-range/ http://pultrex.com/profile-range/ http://www.ncn-uk.co.uk/DesktopDefault.aspx?tabindex=145&tabid=432> http://www.ncn-uk.co.uk/DesktopDefault.aspx?tabindex=145&tabid=432> http://www.lightweight-design.de/index.php;do=show/site=lwd/sid=i44ak0jmje2l33bpcc7ahf6gm2/alloc=135/id=18861 http://www.lightweight-design.de/index.php;do=show/site=lwd/sid=i44ak0jmje2l33bpcc7ahf6gm2/alloc=135/id=18861 http://www.lightweight-design.de/index.php;do=show/site=lwd/sid=i44ak0jmje2l33bpcc7ahf6gm2/alloc=135/id=18861 http://www.lightweight-design.de/index.php;do=show/site=lwd/sid=i44ak0jmje2l33bpcc7ahf6gm2/alloc=135/id=18861

Table of Contents for the Digital Edition of SAMPE Journal - September/October 2016