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J. Compos. Sci.
Volume 9
Issue 12
10.3390/jcs9120669
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This is an early access version, the complete PDF, HTML, and XML versions will be available soon.
Article

Observations from Processing Thick Continuous Fiber Polyphenylene Sulfide (PPS) Laminates with and Without Carbon Black

by
Benjamin N. Dwyer
1,*,
David F. Erb, Jr.
1,
William B. Yori
1,
Danny H. Pham
1,
Scott M. Nelson
1,
Quest O. Teichman
1,
Jonathan R. Roy
1,
Robert J. Hart
2 and
Andrew Q. Smail
2
1
Advanced Structures and Composites Center, University of Maine, Orono, ME 04469, USA
2
U.S. Army DEVCOM Ground Vehicle Systems Center, Warren, MI 48397, USA
*
Author to whom correspondence should be addressed.
J. Compos. Sci. 2025, 9(12), 669; https://doi.org/10.3390/jcs9120669 (registering DOI)
Submission received: 28 July 2025 / Revised: 18 November 2025 / Accepted: 26 November 2025 / Published: 3 December 2025
(This article belongs to the Special Issue Advances in Continuous Fiber Reinforced Thermoplastic Composites)
Versions Notes

Abstract

During the manufacturing and development of a proof-of-concept prototype of a continuous fiber polyphenylene sulfide (PPS) composite vehicle component, unexpected results were observed in thick laminates of an E-glass-fiber-reinforced PPS matrix, which utilized carbon black as a colorant (GF/PPS+CB). Extensive interlaminar macrocracking, transverse intralaminar microcracking, and micro-/macrovoids were observed in GF/PPS+CB laminates after compression forming. When processed under identical conditions, no micro-/macrocracking or voids were present in GF/PPS laminates and carbon fiber/PPS laminates without carbon black colorant. These observations prompted further investigation into the influence of processing conditions, presence of colorant, mold design (open and closed molds), and geometry (flat and curved) on the development of matrix defects in thick continuous fiber-reinforced PPS laminates.
Keywords: polyphenylene sulfide (PPS); carbon black; thermoplastic matrix composites; composite laminates; compression forming; polymer crystallization; carbon fiber; E-glass fiberglass; thick composite polyphenylene sulfide (PPS); carbon black; thermoplastic matrix composites; composite laminates; compression forming; polymer crystallization; carbon fiber; E-glass fiberglass; thick composite

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MDPI and ACS Style

Dwyer, B.N.; Erb, D.F., Jr.; Yori, W.B.; Pham, D.H.; Nelson, S.M.; Teichman, Q.O.; Roy, J.R.; Hart, R.J.; Smail, A.Q. Observations from Processing Thick Continuous Fiber Polyphenylene Sulfide (PPS) Laminates with and Without Carbon Black. J. Compos. Sci. 2025, 9, 669. https://doi.org/10.3390/jcs9120669

AMA Style

Dwyer BN, Erb DF Jr., Yori WB, Pham DH, Nelson SM, Teichman QO, Roy JR, Hart RJ, Smail AQ. Observations from Processing Thick Continuous Fiber Polyphenylene Sulfide (PPS) Laminates with and Without Carbon Black. Journal of Composites Science. 2025; 9(12):669. https://doi.org/10.3390/jcs9120669

Chicago/Turabian Style

Dwyer, Benjamin N., David F. Erb, Jr., William B. Yori, Danny H. Pham, Scott M. Nelson, Quest O. Teichman, Jonathan R. Roy, Robert J. Hart, and Andrew Q. Smail. 2025. "Observations from Processing Thick Continuous Fiber Polyphenylene Sulfide (PPS) Laminates with and Without Carbon Black" Journal of Composites Science 9, no. 12: 669. https://doi.org/10.3390/jcs9120669

APA Style

Dwyer, B. N., Erb, D. F., Jr., Yori, W. B., Pham, D. H., Nelson, S. M., Teichman, Q. O., Roy, J. R., Hart, R. J., & Smail, A. Q. (2025). Observations from Processing Thick Continuous Fiber Polyphenylene Sulfide (PPS) Laminates with and Without Carbon Black. Journal of Composites Science, 9(12), 669. https://doi.org/10.3390/jcs9120669

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