Pultrusion is one of the most efficient methods of producing polymer composite structures with a constant cross-section. Pultruded profiles are widely used in bridge construction, transportation industry, energy sector, and civil and architectural engineering. However, in spite of the many advantages thermoplastic composites have over the thermoset ones, the thermoplastic pultrusion market demonstrates significantly lower production volumes as compared to those of the thermoset one. Examining the thermoplastic pultrusion processes, raw materials, mechanical properties of thermoplastic composites, process simulation techniques, patents, and applications of thermoplastic pultrusion, this overview aims to analyze the existing gap between thermoset and thermoplastic pultrusions in order to promote the development of the latter one. Therefore, observing thermoplastic pultrusion from a new perspective, we intend to identify current shortcomings and issues, and to propose future research and application directions.

The choice of a manufacturing process, raw materials, and process parameters affects the quality of produced pre-consolidated tapes used in thermoplastic pultrusion. In this study, we used two types of pre-consolidated GF/PP tapes—commercially available (ApATeCh-Tape Company, Moscow, Russia) and inhouse-made tapes produced from commingled yarns (Jushi Holdings Inc., Boca Raton, FL, USA)—to produce pultruded thermoplastic Ø 6 mm bars and 75 mm × 3.5 mm flat laminates. Flat laminates produced from inhouse-made pre-consolidated tapes demonstrated higher flexural, tensile, and apparent interlaminar shear strength compared to laminates produced from commercial pre-consolidated tapes by as much as 106%, 6.4%, and 27.6%, respectively. Differences in pre-consolidated tape manufacturing methods determine the differences in glass fiber impregnation and, thus, differences in the mechanical properties of corresponding pultruded composites. The use of commingled yarns (consisting of matrix and glass fibers properly intermingled over the whole length of prepreg material) makes it possible to achieve a more uniform impregnation of inhouse-made pre-consolidated tapes and to prevent formation of un-impregnated regions and matrix cracks within the center portion of the fiber bundles, which were observed in the case of commercial pre-consolidated tapes. The proposed method of producing pre-consolidated tapes made it possible to obtain pultruded composite laminates with larger cross sections than their counterparts described in the literature, featuring better mechanical properties compared to those produced from commercial pre-consolidated tapes.

Under high temperatures, fiber-reinforced polymers are destroyed, releasing heat, smoke, and harmful volatile substances. Therefore, composite structural elements must have sufficient fire resistance to meet the requirements established by building codes and regulations. Fire resistance of composite materials can be improved by using mineral fillers as flame-retardant additives in resin compositions. This article analyzes the effect of fire-retardant additives on mechanical properties and fire behavior of pultruded composite profiles. Five resin mixtures based on vinyl ester epoxy and on brominated vinyl ester epoxy modified with alumina trihydrate and triphenyl phosphate were prepared for pultrusion of strip profiles of 150 mm × 3.5 mm. A series of tests have been conducted to determine mechanical properties (tensile, flexural, compression, and interlaminar shear) and fire behavior (ignitability, flammability, combustibility, toxicity, smoke generation, and flame spread) of composites. It was found that additives impair mechanical properties of materials, as they the take place of reinforcing fibers and reduce the volume fraction of reinforcing fibers. Profiles based on non-brominated vinyl ester epoxy have higher tensile, compressive, and flexural properties than those based on brominated vinyl ester epoxy by 7%, 30%, and 36%, respectively. Profiles based on non-brominated epoxy resin emit less smoke compared to those based on brominated epoxy resin. Brominated epoxy-based profiles have a flue gas temperature which is seven times lower compared to those based on the non-brominated epoxy. Mineral fillers retard the spread of flame over the composite material surface by as much as 4 times and reduce smoke generation by 30%.

Honeycomb weathering is a common phenomenon found on various rock surfaces all around the world. However, honeycomb formation mechanisms are still poorly understood. In this study, we propose a model describing moisture transport within the sandstone and erosion resulting from salt deposition during evaporation of moisture off the rock surface. The moisture transport model is based on the non-linear diffusion equation, where the volumetric moisture content is a combined parameter accounting for the moisture and gas (vapor) content. The moisture transport model accounts for the several-orders-of-magnitude decrease in moisture diffusivity, observed during drying. It was assumed that erosion occurs when the evaporation front is located close to the rock surface. The depth of erosion is proportional to the moisture flow rate through the drying surface. The ABAQUS finite-element software suite was used for numerical solution of the non-linear diffusion equation. The iterative scheme of erosion simulation for different drying cycles was implemented using the Python programming language. Computations were conducted in the 2D setting for the square model with dimensions of 50 mm × 50 mm. Simulation results demonstrate the possibility of obtaining various landform shapes (honeycombs, tafoni) by varying only the value of the distribution of moisture content at the bottom side, simulating the rate of internal wetting of rock.