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oai:figshare.com:article/32640684 2026-10-01T16:29:04Z portal_1172 item_type_8 month_year_10_2026

Computational analysis of interface formation during injection overmoulding of PEEK/PPS hybrid composites Ruaraidh MacLennan (24169437) PUREID: 627607467 Composite injection overmoulding interface multiphase flow computational fluid dynamics thermoplastic crystallinity rheology melting/solidification <p>Composite injection overmouldingis a manufacturing process that allows rapid production of complex compositestructures and with a high degree of precision. This offers an improvement tomany composite manufacturing processes which are typically labour intensive andof low dimensional accuracy. A challenge with composite injection overmouldingis the current lack of predictability of the polymer interface that is formedfollowing contact of molten polymer with the composite insert which isresponsible for the formation of a new hybrid structure. For this reason, theprimary aim of this project was to improve the understanding of interfaceformation mechanisms during composite injection overmoulding for the purpose ofenabling accurate predictions of interface strength. Initially,characterisation of the overmoulded interface was performed which allowed thepresence of a complex morphology to be established. A multi-scale simulationprocess was developed to understand the formation of micro-scale features usingmultiphase flow simulation. A sensitivity between the depth of polymer resinpresent on the composite laminate and the typical flow pattern generated wasestablished for a woven fabric reinforcement. Work in later sections aimed tounderstand the influence of crystallinity on interface formation ascrystallinity is related to polymer interdiffusion. A model was developed to predictthe rheological behaviour of PEEK during crystallisation during bothshear-induced and quiescent conditions which demonstrated less than 5�viation with experimental results up to cooling rates of 20. A method ofpredicting polymer interdiffusion in symmetric semi-crystalline interfaces wasalso proposed for interfaces in a partially crystallised state. The developed crystallinity-basedrheological model was then applied to the micro-scale flow simulation,demonstrating that the presence of crystallinity influenced the characteristicmorphological features.</p><br><i>Thesis is embargoed until 31 July 2027</i>. 2026-10-01T16:29:04Z Text Thesis 10.17034/32640684.v1 https://figshare.com/articles/thesis/Computational_analysis_of_interface_formation_during_injection_overmoulding_of_PEEK_PPS_hybrid_composites/32640684 All Rights Reserved Open Access after 2027-07-31