COMPOSITE MATERIALS UNIT II POLYMER MATRIX COMPOSITES Types Processing Thermo setting matrix composi tes Hand layup

ayup and sprayup techniques filament winding, pultruion, resin transfe r moulding, auctoclave moulding thermoplastic matrix composites Injection mouldi ng, film stacking diaphragm forming thermoplastic tape laying. Glass fibre/polym er interface. Mechanical properties Fracture. Applications. 1

Matrix material in a composite may belong to one of one of these Engineering mat erials: Polymers Metals Ceramics

Classification Composites Based on Reinforcement Based on Matrix Fibrous Particulate Layered MMC Type MMC CMC Matrix PMC Reinforcement Ceramic, metals Metals & alloys CMC Alumina, Silica, BN, Zirconia Metals, ceramics, intermetallics PMC Polyimide, Epoxy, Polyester, Polycarbonate Glass, Metals, Kevlar, Carbon

Importance of Matrix material in a composite: Binds the reinforcements (fibers/particulates) together Transfers the load to the reinforcement Protect the reinforcements from surface damage due to abrasion or chemical attack

POLYMER AS MATRIX MATERIAL

What is a polymer? A polymer is a large molecule (macromolecule) composed of repeating structural u nits typically connected by covalent chemical bonds. The process of forming larg e molecules from small ones is called polymerization. monomers

Polymerisation: This is the process of joining monomers into giant chain like mo lecules is called polymerisation. Methods of Polymerisation: Condensation polymerisation- Stepwise reaction accours in each step- byproducts are formed like water Addition polymerisation- Monomers join to form a polymer w ithout any byproduct. Generally carried out in presence of catalyst.

Comparison of the three polymer categories

Following are the Versatile features of Polymers: Polymer structure are more complex than metals and alloys Lower strength and modulus Can be used in low temperature applications Exposure to UV light and solvent can degrade. Resistant to chemical attacks than metals. Lighter in weight Low cost Easy to process

 Crystal : A homogenous solid formed by a repeating, three-dimensional pattern of atoms, ions, or molecules and having fixed distances between constituent parts. Crystallize : Has a definite, precise, and usually permanent form. Amorphous : Having no definite form or distinct shape.

Melting point and mechanical strength

Some selective thermoplastics and glass temperatures

Factors to be considered in selecting polymer matrix: Molecular Weight Stress Strain Behaviour Thermal Expansion

Comparison of various polymers as matrix materials

Scanning Electron Microscope (SEM) SEM Sputter ion 900 cut 450 cut GFRP rods

SEM image parallel to the fibers' axes GFRP rods

SEM image parallel to the fibers' axes GFRP rods

SEM image perpendicular to the fibers' axes GFRP rods

SEM image perpendicular to the fibers' axes GFRP rods

SEM image 450 to the fibers' axes GFRP rods

SEM image 450 to the fibers' axes GFRP rods

Classification of Polymers

Types of Polymers: Thermosetting Thermoplastics

Types of Polymers (Contd...): Thermosetting: These polymers decompose on heating owing to the crosslinked mole cules in the form of network. Thus they do not soften on heating. They are harde n on curing hence they are thermoset. Curing may be carried out by pressure. Exa mple: Valcanized rubber (rubber cross linked with applying heating and sulphur), It has 10 times strength of natural rubber. Example: Epoxy, phenolic, polyester, polyurethane and silicone.

Thermosets cure by chemical reaction Irreversible Examples Polyester, vinylester Most commo n, lower cost, solvent resistance Epoxy resins Superior performance, relatively costly

Thermosetting Polymers (Contd...): crosslinking of polymeric chains is called as curing. curing can be done by the following methods: Application of heat and pressure Adding an appropriate chemical agent Exposing t he monomer to an electron beam

Thermosets Polyester Polyesters have good mechanical properties, electrical properties and c hemical resistance. Polyesters are amenable to multiple fabrication techniques a nd are low cost. Vinyl Esters Vinyl Esters are similar to polyester in performance. Vinyl esters h ave increased resistance to corrosive environments as well as a high degree of m oisture resistance.

Thermosets Epoxy Epoxies have improved strength and stiffness properties over polyesters. Ep oxies offer excellent corrosion resistance and resistance to solvents and alkali s. Cure cycles are usually longer than polyesters, however no by-products are pr oduced. Flexibility and improved performance is also achieved by the utilization of additives and fillers.

Additives Filler - To impart a variety of performance improvements such as, shrinkage cont rol, surface smoothness, water resistance, cost reduction

Additives * Gel Coat - It provides an aesthetic enhancement to the surface and overall pro tection for the fiberglass laminate. * Additives may include colorants, hardener s, inhibitors, flame retardants and other ingredients.

Types of Polymers(Contd...): Thermoplastics: These polymers flow under the application of heat and pressure. They soften or become plastic on heating. Chains are arranged randomly. Suitable for liquid flow forming. These are solids at room temperature. Example: polyethelene, polystyrene, polymethyl methacrylate(PMMA).

POLYMERS IN USE AS MATRIX MATERIAL

Epoxy: Theromset matrix material. Epoxy is a polymer that contain an epoxide gro up (one oxygen atom and two carbon atom) in its chemical structure. Example: DGEBA (Diglcidyl Ether of Bisphenol A ) Additives were used to modify the characteristics of epoxies. Eg. Diluents are a dded to reduce viscosity. Flexible agents like DETA (ethylenetriamine) are used to make the epoxy flexible. Accelerator may be added to speed the curing process . Other agents are added to protect again ultraviolet radiation.

Characteristics of Epoxy: Better Moisture Resistance Low shrinkage Good adhesion with Reinforcement

Polyester: A condensation reaction between a glycol (ethylene, propylene, diethy lene glycol) and an unsaturated dibasic acid (maleic or fumaric) results in poly ster. This contains a double bond C=C between its corbon atoms. Unsaturated- mea ns there are some reactive sites. Example: poly ethylene terephthalate PET Diluents are used to reduce the viscosity of polymer. Curing, accelerator (cobol t napthalate) and hardened agents are usually added for strength.

Charecteristics of Polyester: Cheap Resistance to variety of chemicals Adequate moisture resistance

Polyetherether ketone(PEEK): Well known for its toughness Higher melting point Polyphenylene sulfide (PPS): Modest molecular weight Low Shrinkage Polyethersulf one (PES): High Thermal stability High Mechanical strength

Applications for Epoxides adhesive to metals and composites. (Thermosets) Bonding and adhesives: Automotive and aircraft industries Molding, casting and tooling: Molding compounds in electrical and electronic ind ustries, casting resins, potting resins. Prototype and master model tools. Lamin ating and composites: Binders in fiber reinforced laminates and composites. Lami nates are used in printed wiring boards. Composite applications include filament winding (high performance pipes in oil fields, pressure vessels, tank and rocket motor housing s), pultrusion, casting, and molding (graphite composites for aerospace applicat ions).

Applications for Epoxides (Thermosets) Building and construction: Flooring (seamless, self-leveling, or epoxy terrazzo floors), repair of bridges and roads with glass and carbon fiber wraps, concrete crack repair, coat reinforcing bars, binders for patios, swimming pool decks, a nd soil around oil-well drills. Protective coatings: maintenance coatings for in dustrial and marine, tank linings, industrial floorings, beer and beverage can coatings, food cans, appliance primers, hospital and laboratory furniture.

Comparison of various polymers as matrix materials

UNIT II POLYMER MATRIX COMPOSITES: Types Processing Thermo sensing matrix composites Hand layup and sprayup techniq ues filament winding, pultruion, resin transfer moulding, auctoclave moulding th ermoplastic matrix composites Injection moulding, film stacking diaphragm formin g thermoplastic tape laying. Glass fibre/polymer interface. Mechanical propertie s Fracture. Applications.

Classification based on Matrices Composite materials Matrices Polymer Matrix Composites (PMC) Metal Matrix Composites MMC) Ceramic Matrix Composites (CMC) Thermoset Thermoplastic Rubber

What is a polymer? Poly many mer repeat unit A polymer is a large molecule (macromolecule) composed of repeating structural u nits typically connected by covalent chemical bonds Examples of polymers: repeat unit repeat unit repeat unit H H H H H H C C C C C C H H H H H H Polyethylene (PE) H H H H H H C C C C C C H Cl H Cl H Cl Polyvinyl chloride (PVC) H C H H H C C CH3 H H H C C CH3 H H C CH3 Polypropylene (PP)

Polymer Matrix Composite (PMC) is the material consisting of a polymer (resin) m atrix combined with a fibrous reinforcing dispersed phase. Polymer Matrix Compos ites are very popular due to their low cost and simple fabrication methods.

Polymer(Matrix) Composite (Matrix + Reinforcement) Discontinuous phase - Reinforcement Continuous phase - Matrix Reinforcements Pri ncipal load bearing member. Matrix provides a medium for binding and holding the reinforcements together into a solid. protects the reinforcement from environme ntal degradation. serves to transfer load from one insert (fibre, flake or parti cles) to the other. Provides finish, colour, texture, durability and other funct ional properties.

Classification of Polymers Linear polymer - Any polymer in which molecules are in the form of chains. Therm oplastic polymers - Linear or branched polymers in which chains of molecules are not interconnected to one another. Thermosetting polymers - Polymers that are h eavily cross-linked to produce a strong three dimensional network structure. Ela stomers - These are polymers (thermoplastics or lightly cross-linked thermosets) that have an elastic deformation > 200%.

Molecular chain configurations: a. Linear b. Branched c. Crossed linked d. Ladde r

Thermosetting resins are the most widely used polymers in PMCs. Epoxy and polyes ter are commonly mixed with fiber reinforcement. The most widely used form is a laminar structure, made by stacking and bonding thin layers of fiber and polymer until the desired thickness is obtained. Fibers in PMCs Reinforcement in Variou s forms: discontinuous (chopped), continuous or woven as a fabric Principal fibe r materials in FRPs are glass, carbon, and Kevlar 49. Less common fibers include boron, SiC, Al2O3 and steel. Glass (in particular E-glass) is the most common f iber material in todays FRPs; its use to reinforce plastics from 1920 onwards.

Forms of glass fibers a. Chopped strand b. Continuous yarn c. Roving d. Fabric

Polymerisation: This is the process of joining monomers into gaint chain like mo lecules. Methods of Polymerisation: Condensation polymerisation Addition polymer isation Degree of polymerization = No of monomer units in a chain 103 to 105

Thermosets Thermoset materials are usually liquid or malleable prior to curing, and designe d to be molded into their final form. Has the property of undergoing a chemical reaction by the action of heat, catalyst, ultraviolet light, etc., to become a r elatively insoluble and infusible substance. They develop a well-bonded three-di mensional structure upon curing. Once hardened or cross-linked, they will decomp ose rather than melt. Thermoset materials are generally stronger than thermoplas tic materials due to this 3-D network of bonds, and are also better suited to hi gh-temperature applications up to the decomposition temperature of the material.

 Thermosets are made by mixing two components (a resin and a hardener: eg Eraldit e (liquid state) to increase bonding strength of fibre and matrix) which react a nd harden, either at room temperature or on heating. The resulting polymer is us ually heavily cross-linked, so thermosets are also called as network polymers. T he cross-links form during the polymerisation of the liquid resin and hardener, so the structure is almost always amorphous. On reheating the crosslinks prevent true melting or viscous flow so the polymer cannot be hot-worked. Further heati ng just causes it to decompose.

Thermosets Extensive cross-linking formed by covalent bonds. Bonds prevent chains moving re lative to each other.

Types of Thermosetting plastics

Epoxy: Epoxy is a polymer that contain an epoxide group in its chemical structur e. Example: DGEBA (Diglcidyl Ether of Bisphenol A ) Charecteristics of Epoxy: Better Moisture Resistence Low shrinkage Good adhersio n with Reinforcement

Polyester: A condensation reaction between a glycol and an unsaturated dibasic a cid results in polyster. This contains a double bond C=C between its carbon atom s. Example: poly ethylene terephthalate (PET). Charecteristics of Polyester: Che ap Resistance to variety of chemicals Adequate moisture resistance

Comparison of various polymers as matrix materials

Thermosetting plastics - applications

Thermoplastics In thermoplastic polymer, individual molecules are linear in structure with no c hemical linking between them. They are held in place by weak secondary bond (intermolecular force), such as va nder Walls bonds and hydrogen.

 Some thermoplastics normally do not crystallize, they are termed as"amorphous" p lastics and are useful at temperatures below the Tg. Generally, amorphous thermoplastics are less chemically resistant.

Thermoplastics (80%) No cross links between chains. Weak attractive forces between chains broken by w arming. Change shape - can be remoulded. Weak forces reform in new shape when co ld.

Reasons for the use of thermoplastic matrix composites Refrigeration is not necessary with a thermoplastic matrix. Parts can be made an d joined by heating. Parts can be remolded, and any scrap can be recycled. Therm oplastics have better toughness and impact resistance than thermosets. Shorter fabrication time. Can be recycled.

UNIQUE CHARACTERISTIC OF THERMOPLASTIC Near to glass transition temperature Tg, polymeric materials changes a hard soli d to soft, tough ( leather like) solid. Over a temperature range around Tg.Near this temperature, the materials is also highly viscoelastic. When load is applie d it exhibit Elastic deformation. With increasing temperature polymer changes in to rubberlike solid undergoing deformation on external load. Further increasing the temp both amorphous and semicrystallline thermoplastic achieve highly viscou s state and attain the melting temp Tm. Variation of Tensile modulus with temperature for Amorphous and Semi crytaline t hermoplastic.

 Thermoplastic polymer have higher strain-to-failure.

Types of Thermoplastics

COMPARISON OF THE THREE POLYMER CATEGORIES

Thermoplastics Vs Thermosets

Functions of Polymer Matrix Holds the fibres together. Protects the fibres from environment. Distributes the loads evenly between fibres so that all fibres are subjected to the same amount of strain. Enhances transverse properties of a laminate. Improves impact and fr acture resistance of a component. Helps to avoid propagation of crack growth thr ough the fibres by providing alternate failure path along the interface between the fibres and the matrix. Carry inter-laminar shear.

Desired Properties of a Polymer Matrix Reduced moisture absorption. Low shrinkage. Low coefficient of thermal expansion . Good flow characteristics so that it penetrates the fibre bundles completely a nd eliminates voids during the compacting/curing process. Must be elastic to tra nsfer load to fibres.

Desired Properties of a Polymer Matrix Reasonable strength, modulus and elongation (elongationshould be greater than fi bre). Strength at elevated temperature (depending on application). Low temperature capability (depending on application). Excellent chemical resistance (depending on application). Should be easily processable into the final composite shape. Dimensional stability (maintains its shape).

Effect of Temperature on Thermoplastics Degradation temperature (Tm) - The temperature above which a polymer burns, chars, or decomposes. Glass temperature (Tg) The temperature range below which the polymer The effect of temperature on the modulus of elasticity for an amorphous thermoplastic. amorphous assumes a rigid glassy structure.

Glass transition temperature: The liquid-glass transition (or glass transition for short) is the reversible tr ansition in amorphous materials (or in amorphous regions within semicrystalline materials) from a hard and relatively brittle state into a molten or rubber-like state. An amorphous solid that exhibits a glass transition is called a glass. Supercooling a viscous liquid into the glass state is called vitrification. Polymer can have both a glass transition temperature and a melting temperature. But you should know that the amorphous portion undergoes the glass transition on ly, and the crystalline portion undergoes melting only.

Glass transition temperature: Have you ever left a plastic bucket or some other plastic object outside during the winter, and found that it cracks or breaks more easily than it would in the summer time? What you experienced was the phenomenon known as the glass transiti on. This transition is something that only happens to polymers. There is a certa in temperature(different for each polymer) called the glass transition temperatu re, or Tg for short. When the polymer is cooled below this temperature, it becom es hard and brittle, like glass. Some polymers are used above their glass transi tion temperatures, and some are used below. Hard plastics like polystyrene and p oly(methyl methacrylate), are used below their glass transition temperatures; th at is in their glassy state. Their Tgs are well above room temperature, both at around 100 oC. Rubber elastomers like polyisoprene and polyisobutylene, are used above their Tgs, that is, in the rubbery state, where they are soft and flexible.

Temperature Effect on Polymers

Service temp for selected Polymeric matrices

Properties of General-Purpose Thermoplastics

Application of plastic materials

Stress-strain behavior of different polymer matrices Thermoplastic polymers 80 70 60 Stress (Mpa) Polysulfon Thermosetting polymers 90 80 70 Stress (Mpa) Polyester Phenolic Epoxy 50 40 Polyamid 60 50 40 30 20 10 0 30 20 10 0 0 100 200 300 Strian(% ) Polyethylene 400 500 0 1 2 3 Strian(% ) 4 5 Notice to the range of ultimate strains of different polymers

Comparision of various polymers as matrix materials

Limitations of PMC Low working temperature. High coefficient of thermal expansion- dimensional inst ability Sensitivity to radiation and moisture. Processing temperature are genera lly higher than those with thermosets.

UNIT II Types POLYMER MATRIX COMPOSITES: Processing Thermo setting matrix composites Hand layup and sprayup techniques filament winding, pultruion, resin transfer moulding, auctoclave moulding thermoplastic matrix composites Injection moulding, film stacking diaphragm forming thermoplastic tape laying. Glass fibre/polymer interface. Mech anical properties Fracture. Applications.

Polymer Processing Forming Processes for Thermosetting matrix composites: Hand layup and sprayup techniques. Filament winding. Pultrusion. Resin transfer moulding. Autoclave moulding. Forming Processes for Thermoplastic matrix composites: Injection moulding. Film stacking. Diaphragm forming. Thermoplastic tape laying.

Two Main Processing Steps The processing of fiber reinforced laminates can be divided into two main steps: Lay-up Curing Layup basically is the process of arranging fiberreinforced layers (laminae) in a laminate and shaping the laminate to make the part desired. Curing- A polymerization process transforming the liquid resin to a solid creati ng the maximum physical properties attainable from the materials.

Hand Lay-up Hand layup, or contact molding, is the oldest and simplest way of making fibergla ssresin composites.

Hand Lay-up Fibers can be laid onto a mold by hand. Resin is sprayed or brushed on. Applications are standard wind turbine blades, boats, etc.

Hand Layup Hand layup process:

Gel coat (anti-adhesive agent )is

applied to open mold. Base resin mixed with catalysts is applied by pouring and brushing. Dry reinforcement (fiberglass) is placed in the mold. Layup is made by building layer upon layer to obtain the desired thickness.

Hand Layup The Hand Layup is a manual, slow, labor consuming method, which involves the following operations: The mold is coated by a release anti-ad hesive agent, preventing sticking the molded part to the mold surface. The prime surface layer of the part is formed by applying gel coating. A layer of fine fiber reinforcing tissue is applied. Layers of the liquid matrix resin and reinforcing fibers in form of woven fabric, rovings or chopped strand s are applied. The resin mixture may be applied by either brush or roll. The part is cured (usu ally at room temperature). Then the part is removed from the mold surface. The disadvantages of the Hand Layup method are: low concentration of reinforcing phase (up to 30%) and low densification of the composites (entrapped air bubble s).

Hand Layup Advantages: Widely used. Low tooling cost. Custom shape. Larger and complex item s can be produced. Potential Problems: Labour intensive. Low-volume process. Sty rene emission. Quality control is entirely dependent on the skill of labourers.

Hand layup products:

Hand layup products:

Spray-up In Sprayup process, chopped fibers and resins are sprayed simultaneously into or onto the mold. Applications are lightly loaded structural panels, e.g. caravan bodies, truck fa irings, bathtubes, small boats, etc

Spray up Process

SPRAYUP In Sprayup process liquid resin matrix and chopped reinforcing fibers ar e sprayed by two separate sprays onto the mold surface. The roven fibers are cho pped into fibers of 1-2 (25-50 mm) length and then sprayed by an air jet simultaneously with a resin spray at a predetermined ratio between the reinforcing and matrix phase. The Sprayup method permits rapid formation of uniform composite coating, however the mechanical properties of the material are moderate since the method is unable to use continuous reinforcing fibers.

SPRAYUP A spray gun supplying resin in two converging streams into which roving is chopped. Automation with robots results in high rate of production. Labor cos ts are lower.

Sprayup process: In Sprayup process, chopped fibers and resins are sprayed simultaneously into or onto the mold. Applications are lightly loaded structural panels, e.g. caravan bodies, truck fairings, bathtubs, small boats, e tc

Hand and Spray Layup In both the cases the deposited layers are densified with rollers. Catalysts and Accelerators are used. * Catalyst - substance added to the gel coat or resin to initiate the curing process. * Accelerator (cobolt napthalate) - A compound add ed to speed up the action of a catalyst in a resin mix. Curing at room temperature or at a moderately high temperature in an oven.

Advantages of Hand Layup and Sprayup Tooling cost is low. Semiskilled workers are easily trained. Design Flexibility. Molded-in inserts and structural changes are possible. Sandwich constructions a re possible. Large and Complex items can be produced. Minimum equipment investme nt is necessary. The startup lead time and the cost are minimal.

Disadvantages of Hand Layup and Sprayup Labor Intensive. Low volume process. Longer curing times. Production uniformity is difficult. Waste factor is high.

Advantages of Hand Lay up and Spray Lay -up Tooling cost is low. Semiskilled workers are easily trained. Design Flexibility. Molded-in inserts and structural changes are possible. Sandwich constructions a re possible.

Advantages of Hand Lay up and Spray Lay -up Large and Complex items can be produced. Minimum equipment investment is necessa ry. The startup lead time and the cost are minimal.

Disadvantages of Hand Lay up and Spray Lay -up Labor Intensive. Low volume process. Longer curing times. Production uniformity is difficult. Waste factor is high.

PREPREG

Prepreg is the industry's term used by composite manufactures for preparing composite material based on their requirements

Pre-impregnated with a polymer resin that is only partially cured.

Prepreg is delivered in tape form to the manufacturer who then molds and fully cures the product without having to add any resin.

This is the composite form most widely used for structural applications.

PREPREG PROCESS Manufacturing begins by collimating a series of spool-wound continuous fiber tow s. Tows are then sandwiched and (Partially cured) pressed between sheets of release and carrier paper using heated rollers (calendering). The release paper sheet has been

coated with a thin film of heated resin solution to provide for its thorough impregnation of the fibers. The final prepre g product is a thin tape consisting of continuous and aligned fibers embedded in a partially cured resin.

PREPREG Prepared for packaging by winding onto a cardboard core. Typical tape thicknesse s range between 0.08 and 0.25 mm Tape widths range between 25 mm and 1525 mm. Re sin content lies between about 35 and 45 vol%

PREPREG

The prepreg is stored at 0 C (32 ons at room temperature.

F) or lower because matrix undergoes curing reacti

Also the time in use at room temperature must be minimized. Life time is about 6 months if properly handled. Both thermoplastic and thermosetting resins are uti lized: carbon, glass, and aramid fibers are the common reinforcements. Actual fa brication begins with the lay-up. Normally a number of plies are laid up to prov ide the desired thickness. The layup can be by hand or automated. Easily obtaine d with epoxies.

Polymer Processing Forming Processes for Thermosetting matrix composites: Hand layup and sprayup techniques. Filament winding. Pultrusion. Resin transfer moulding. Autoclave moulding. Forming Processes for Thermoplastic matrix composites: Injection moulding. Film stacking. Diaphragm forming. Thermoplastic tape laying.

Filament winding

Filament Winding The Winding of roving can be polar (hoop) or helical.

Filament Winding Processing Types - Wet winding * Low viscosity resin (< 2000 centipoise). * Polyesters, epoxies are examples - Prepeg winding * hot melt or solvent dip process is used. * high viscosity epoxies, polyamides are examples.

Filament Winding Curing done at elevated temperature. Void sites are roving cross overs and regio ns between layers with different fiber orientation. In the Manufacturing of Very large vessels of cylindrical and spherical shapes.

Filament Winding

Filament Winding Filament Winding method involves a continuous filament of reinforcing material wound onto a rotating mandrel in layers or at different layers. If a li quid thermosetting resin is applied on the filament prior to winding the, proces s is called Wet Filament Winding. If the resin is sprayed onto the mandrel with wound filament, the process is called Dry Filament Winding. Besides conventional curing of molded parts at room temperature, Autoclave curing (high temp) may be used.

Filament Winding Filament Winding Process For Round or Cylindrical parts A tape of resin impregnated fibers is wrapped ove r a rotating mandrel to form a part. These windings can be helical or hooped. Th ere are also processes that use dry fibres with resin application or prepregs ar e used. Parts vary in size from 1" to 20' Winding direction Hoop/helical layers Layers of different material High strength s are possible due to winding designs in various direction Winding speeds are ty pically 100 m/min and typical winding tensions are 0.1 to 0.5 kg.

Filament Winding Demolding To remove the mandrel, the ends of the parts are cut off when appropri ate, or a collapsible mandrel (e.g., low melt temperature alloys ) is used. Curi ng in done in an Autoclave for thermoset resins (polyester, epoxy, phenolic, sil icone) and some thermoplastics (PEEK) Fibers are E-glass, S-glass, carbon fiber and aramids (toughness and lightweight) . Inflatable mandrels can also be used t o produce parts that are designed for high pressure applications, or parts that need a liner, and they can be easily removed.

Filament Winding Advantages Wide variety of part sizes can be produced Parts can be made with str ength in several different directions Very less scrap rate Non-cyclindrical parts can be formed after winding Flexible mandrels can be prep ared Reinforcement panels and fittings can be inserted during winding Due to hig h hoop stress, parts with high pressure ratings can be made Disadvantages Viscosity and life of resin must be carefully chosen NC programming can be difficult Some shapes cant be made with filament winding Factors such as filament tension must be controlled

Filament Winding

Filament winding - applications Pressure vessels, storage tanks and pipes Rocket motors, launch tubes Light Anti-armour Weapon (LAW) Hunting Engineering made a nesting pair in 4 minutes with ~20 mandrels circulate d through the machine and a continuous curing oven. Drive shafts Entec the world's largest five-axis filament winding machine for wind turbine blades length 45.7 m, diameter 8.2 m, weight > 36 tonnes.

FILAMENT WINDING CHARACTERISTICS The cost is about half that of tape laying Productivity is high (50 kg/h). Applicat ions include: fabrication of composite pipes, tanks, and pressure vessels. Carbon fiber reinforced rocket motor cases used for Space Shuttle and o ther rockets are made this way. Tensioner

Filament winding

Filament winding - winding patterns hoop (90) - circumferential winding angle is normally just below 90 degrees each complete rotation of the mandrel shi fts the fibre band to lie alongside the previous band. helical complete fibre co verage without the band having to lie adjacent to that previously laid. polar domed ends or spherical components fibres constrained by bosses on each po le or hoop (90) of the component. axial (0) beware: difficult to maintain fibre tension

Filament winding patterns hoop : helical: polar:

 Kevlar component

Filament wound pressure bottles for gas storage

Polymer Processing Forming Processes for Thermosetting matrix composites: Hand layup and sprayup techniques. Filament winding. Pultrusion. Resin transfer moulding. Autoclave moulding. Forming Processes for Thermoplastic matrix composites: Injection moulding. Film stacking. Diaphragm forming. Thermoplastic tape laying.

Pultrusion Continuous process that pulls a fiber through a resin impregnation bath and thro ugh a shaping die. The dimensions and shape of the die will define the finished part being fabricated. Inside the metal die, precise temperature control activates the curing of the th ermoset resin. The solid laminate will be cut to the desired length.

Pultrusion

Pultrusion

Pultrusion

Pultrusion Shapes such as rods, channels, angle and flat stocks can be easily produced. Pro duction rate is 10 to 200 cm/min. Profiles as wide as 1.25 m with more than 60% fiber volume fraction can be made routinely. No bends or tapers allowed (continu ous molding cycle)

Pultrusion Fiber reinforcements in different forms can be used (continuous strand mat, Chop ped strand mat stitched to a carrier material) . Common resins used are epoxy, polyester etc.

Pultrusion Manufacturing Fibers are brought together over rollers, dipped in resin and drawn through a he ated die. A continuous cross section composite part emerges on the other side. Pultruted

Pultrusion Description: Pultrusion is a process where composite parts are manufactured by p ulling layers of fibres/fabrics, impregnated with resin, through a heated die, t hus forming the desired cross-sectional shape with no part length limitation.

Pultrusion Pultrusion is an automated, highly productive process of fabrication of Polymer Matrix Composites in form of continuous long products of constant cross-section. A scheme of the process is presented on the picture:

Pultrusion Pultrusion process involves the following operations: Reinforcing fibers are pul led from the creels. Fiber (roving) creels may be followed by rolled mat or fabr ic creels. Pulling action is controlled by the pulling system. Guide plates coll ect the fibers into a bundle and direct it to the resin bath. Fibers enter the r esin bath where they are wetted and impregnated with liquid resin. Liquid resin contains thermosetting polymer, pigment, fillers, catalyst and other additives. The wet fibers exit the bath and enter preformer where the excessive resin is sq ueezed out from fibers and the material is shaped. The preformed fibers pass through the heated die where the final cross-section d imensions are determined and the resin curing occurs. The cured product is cut on the desired length by the cut-off saw.

Pultrusion Pultrusion process is characterized by the following features: High productivity . The process parameters are easily controllable. Low manual labor component. Pr ecise cross-section dimensions of the products. Good surface quality of the products. Homogeneous distribution and high concentration of the reinforcing fibers in the material is achieved (up to 80% of roving reinforcement, up to 50% of mixed mat + roving reinforcement). Pultrusion is used for fabrication of Fiber glass or Carbon fiber or Kevlar (ara mid) fiber reinforced polymer composites.

Pultrusion Used for production of constant cross-section composite profiles

Pultrusion Design Hollow parts can be made using a mandrel that extends out the exit side of the d ie. Variable cross section parts are possible using dies with sliding parts. Two mai n types of dies are used, fixed and floating. Fixed dies can generate large forc es to wet fiber. Floating dies require an external power source to create the hy draulic forces in the resin. Multiple dies are used when curing is to be done by the heated dies.

Pultrusion Very low scrap. Up to 95% utilization of materials (75% for layup). Rollers are used to ensure proper resin impregnation of the fiber. Material form s can also be used at the inlet to the die when materials such as mats, weaves, or stitched material is used. For curing, tunnel ovens can be used. After the part is formed and gelled in the die, it emerges, enters a tunnel oven where curing is completed. Another method is, the process runs intermittently with sections emerging from the die, and the pull is stopped, split dies are brought up to the sections to cure it, they then retract, and the pull continues. (Typical lengths for curing are 6" to 24").

 Materials Pultrusion Most fibers are used (carbon, glass, aramids) and Resins must be fast curing bec ause of process speeds (polyester and epoxy) . Processing speeds are 0.6 to 1 m/ min; thickness are 1 to 76 mm; diameters are 3 mm to 150mm double clamps, or bel ts/chains can be used to pull the part through. The best designs allow for conti nuous operation for production. diamond or carbide saws are used to cut sections of the final part. The saw is designed to track the part as it moves. these par ts have good axial properties.

Pultrusion Advantages good material usage compared to layup high throughput and higher resi n contents are possible Disadvantages part cross section should be uniform. Fibe r and resin might accumulate at the die opening, leading to increased friction causing jamming, and breakage. when excess resin is used, part strength will decrease void can result if the di e does not conform well to the fibers being pulled quick curing systems decrease strength

Pultrusion Advantages: Potential Problems: Minimal kinking of fibres/fabrics Rapid processing Improper fibre wet-out Fibre breakage Inadequate cure Low material scrap rate Die jamming Good quality control

Complex die design

Pultrusion -characteristics seek uniform thickness in order to achieve uniform cooling and hence minimise re sidual stress. hollow profiles require a cantilevered mandrel to enter the die from the fibre-feed end. continuous constant cross-section profile normally thermoset (t hermoplastic possible) impregnate with resin pull through a heated die resin shr inkage reduces friction in the die polyester easier to process than epoxy tensio n control as in filament winding post-die, profile air-cooled before gripped han d-over-hand hydraulic clamps conveyor belt/caterpillar track systems. moving cut -off machine ("flying cutter"). The solid laminate will be cut to the desired le ngth Inside the metal die, precise temperature control activates the curing of t he thermoset resin.

 Shapes such as rods, channels, angle and flat stocks can be easily produced. Production rate is 10 to 200 cm/min. Profiles as wide as 1.25 m with more than 60% fiber volume fraction can be made routinely. No bends or tapers allowed (continuous molding cycle)

Pultrusion -applications panels beams gratings ladders tool handles - ski poles kites electrical ins rs and enclosures light poles - hand rails roll-up doors 450 km of cable trays i n the Channel Tunnel Rod better properties than steel

Pultrusion Applications Advanced Composite Construction System components: plank ............... and con nectors used in Aberfeldy and Bonds Mill Lock bridges http://

Polymer Processing Forming Processes for Thermosetting matrix composites: Hand layup and sprayup techniques. Filament winding. Pultrusion. Resin transfer moulding. Autoclave moulding. Forming Processes for Thermoplastic matrix composites: Injection moulding. Film stacking. Diaphragm forming. Thermoplastic tape laying.

Resin Transfer Molding In the RTM process, dry (i.e. non-impregnated ) reinforcement is preshaped and o riented into skeleton of the actual part known as the preform which is inserted into a matched die mold. The heated mold is closed and the liquid resin is injec ted The part is cured in mold. The mold is opened and part is removed from mold.

Resin Transfer Moulding Close mold low pressure process. A dry preform is placed in a matched metal die. A vaccum pulls the Low viscosity resin through a flow medium that helps impregnate the preform. Resin may also be forced by means of a pump.

Resin Transfer Moulding

RTM Transfer Molding (Resin Transfer Molding) is a Closed Mold process in which a pr eweighed amount of a polymer is preheated in a separate chamber (transfer pot) a nd then forced into a preheated mold filled with a reinforcing fibers, taking a shape of the mold cavity, impregnating the fibers and performing curing due to h eat and pressure applied to the material. The method uses a split mold and a thi rd plate equipped with a plunger mounted in a hydraulic press. The method combin es features of both Compression Molding - hydraulic pressing, the same molding m aterials (thermosets) and Injection Molding ram (plunger), filling the mold thro ugh a sprue. Transfer Molding cycle time is shorter than Compression Molding cyc le but longer than Injection Molding cycle. The method is capable to produce very large parts (car body shell), more complic ated than Compression Molding, but not as complicated as Injection Molding.

Transfer Molding process involves the following steps: The mold cavity is filled with preformed reinforcing fibers. A pre-weighed amount of a polymer mixed with additives and fillers (charge) is placed into the transfer pot. The charge may be in form of powders, pellets, putty-like masses or preRTM formed blanks. The charge is heated in the pot where the polymer softens. The plunger, mounted on the top plate, moves downwards, pressing on the polymer charge and forcing it to fill the mold cavity through the sprue and impregnate the fibers. The mold, equipped with a heating system, provides curing (cross-linking) of the polymer (if thermoset is processed). The mold is opened and the part is removed from it by means of the ejector pin. If thermosetting resin is molded, the mold may be open in hot state cured thermosets maintain their shape and dimensions even in hot state. If thermoplastic is molded, the mold and the molded part are cooled down before opening. The scrap left on the pot bottom (cull), in the sprue and in the channe ls is removed. Scrap of thermosetting polymers is not recyclable.

Resin Transfer Molding (RTM) Mold design is critical (Resin flow and heat transfer are analyzed to obtain an optimal mold design).

Advantages of RTM Large complex shapes and curvatures can be made easily. High level of automatio . Lay-up is simpler than in manual operations. Takes less time to produce. Fiber volume fractions as high as 60% can be achieved. Styrene emission can be reduce d to a minimum. Cost effective High volume process for large-scale processing.

Disadvantages of RTM are Mold design is complex and requires moldfilling analysis. Fiber reinforcement ma y "wash" or move during resin transfer.

Advantages of RTM Large complex shapes and curvatures can be made easily. High level of automation . Layup is simpler than in manual operations. Takes less time to produce. Fiber volume fractions as high as 60% can be achieved. Styrene emission can be reduced to a minimum. Cost effective High volume process for large-scale processing.

Disadvantages of RTM Mold design is complex and requires mold-filling analysis. Fiber reinforcement m ay "wash" or move during resin transfer.

Resin Transfer Moulding Advantages: Potential Problems: Low skill labour required Low tooling cost Low volatile emission Required design tailorability

Control of resin flow Kinking of fibres Criticality in mould design The method is capable to produce very large parts (car body shell), more complic ated than Compression Molding, but not as complicated as Injection Molding.

RTM Products:

Polymer Processing Forming Processes for Thermosetting matrix composites: Hand layup and sprayup techniques. Filament winding. Pultrusion. Resin transfer moulding. Autoclave moulding. Forming Processes for Thermoplastic matrix composites: Injection moulding. Film stacking. Diaphragm forming. Thermoplastic tape laying.

Autoclave moulding Autoclave Curing is a method in which a part, molded by one of the open molding methods, is cured by a subsequent application of vacuum, heat and inert gas pres sure. The molded part is first placed into a plastic bag, from which air is exha usted by a vacuum pump. This operation removes air inclusions and volatile produ cts from the molded part. Then heat and inert gas pressure are applied in the autoclave causing curing and densification of the material. Autoclave Curing enables fabrication of consistent homogeneous materials. The me thod is relatively expensive and is used for manufacturing high quality aerospac e products. An autoclave is a closed vessel (round or cylindrical) in which processes occur under simultaneous application of high temperature and pressure.

Autoclave An oven that allows for high pressures to be used. Composites cure under heat an d pressure provides a superior part because the voids are reduced due to the pre ssure. Process The part is placed in the pressure vessel, and heated, pressure i s applied simultaneously. Vacuum bagging can be used in an autoclave. Thermoset composites are crosslinked. Thermoplastics are melted. Advantages The pressure h elps bond composite layers, and remove more voids in the matrix. Very large part s can be made with high fiber loadings. Properties are improved. Many different parts can be cured at the same time. Disadvantages Autoclaves are expensive

a) b) a) Autoclave process to make a laminated composite b) Prepregs of different orie ntations stacked to form a laminated composite Higher fiber volume fractions (60 65%) can be obtained

Autoclave process- Charcteristics Very high quality product Generally prepregs are used Chopped fibres with resin can also be used Hybrid composites can be produced High fibre volume fractions c an be obtained simultaneous application of high temperature and pressure helps i n, * Consolidating the laminate. * Removing the entrapped air. * Curing the poly meric matrix.

Autoclave Moluding

Autoclave Molding Applications are lighter, faster and more agile fighter aircraft, motor sport ve hicles.

Polymer Processing Forming Processes for Thermosetting matrix composites: Hand layup and sprayup techniques. Filament winding. Pultrusion. Resin transfer moulding. Autoclave moulding. Forming Processes for Thermoplastic matrix composites: Injection moulding. Film stacking. Diaphragm forming. Thermoplastic tape laying.

Injection moulding Injection Molding is a Closed Mold process in which molten polymer (commonly the rmoplastic) mixed with very short reinforcing fibers (10-40%) is forced under hi gh pressure into a mold cavity through an opening (sprue). Polymer-fiber mixture in form of pellets is fed into an Injection Molding machine through a hopper. T he material is then conveyed forward by a feeding screw and forced into a split mold, filling its cavity through a feeding system with sprue gate and runners. S crew of injection molding machine is called reciprocating screw since it not onl y rotates but also moves forward and backward according to the steps of the mold ing cycle. It acts as a ram in the filling step when the molten polymer-fibers m ixture is injected into the mold and then it retracts backward in the molding st ep. Heating elements, placed over the barrel, soften and melt the polymer. The m old is equipped with a cooling system providing controlled cooling and solidific ation of the material.

Injection moulding The polymer is held in the mold until solidification and then the mold opens and the part is removed from the mold by ejector pins. Injection Molding is used ma inly for thermoplastic matrices, but thermosetting matrices are also may be extruded. In this case curing (cross-linking) occurs during heating and melting of the material in the barrel. A principal scheme of an Injection Molding Machine is shown in re below. Injection Molding is highly productive method providing high and control of shape of the manufactured parts. The method is profitable heated the pictu accuracy in

mass production of large number of identical parts. One of the disadvantages of the method is limited length of fibers decreasing th eir reinforcing effect.

Injection moulding

Injection moulding machine The injection molding machine comprises of: The plasticating and injection unit: The major tasks of the plasticating unit are to melt the polymer, to accumulate the melt in the screw chamber, to inject the melt into the cavity and to mainta in the holding pressure during cooling. The clamping unit: It's role is to open an d close the mold, and hold the mold tightly to avoid flash during the filling an d holding. Clamping can be mechanical or hydraulic. The mold cavity: The mold is the central point in an injection molding machine. Each mold can contain multip le cavities. It distributes polymer melt into and throughout the cavities, shape s the part, cools the melt and ejects the finished product.

The Injection Mold The mold consists Sprue and runner system Gate Mold cavity Cooling system (for t hermoplastics) Ejector system Features of injection molding Direct path from molding compound to finished product Process can be fully autom ated High productivity & quality

Injection molding machine

Injection Molding Machine

INJECTION MOLDING Thermoplastics : Polystyrene,PE, PP, ABC, PC,PMMA etc

Injection Molding Cycle Injection molding involves two basic steps: Melt generation by a rotating screw Forward movement of the screw to fill the mold with melt and to maintain the inj ected melt under high pressure Injection molding is a cyclic process: Injection: The polymer is injected into the mold cavity. Hold on time: Once the cavity is filled, a holding pressure is maintained to compensate for material sh rinkage. Cooling: The molding cools and solidifies. Screw-back: At the same time , the screw retracts and turns, feeding the next shot in towards the front Injec tion molding is the most important process used to manufacture plastic products. It is ideally suited to manufacture mass produced parts of complex shapes requi ring precise dimensions. It is used for numerous products, ranging from boat hul ls and lawn chairs, to bottle cups. Car parts, TV and computer housings are inje ction molded.

Thermosets : Unsaturated polyester resin, Phenol formaldehyde etc

Injection Molding

Injection molding As pointed out earlier, Thermoplastics soften on heating, and therefore melt flo w techniques of forming can be used. Such techniques include injection molding, extrusion , and thermoforming. Thermoforming involves the production of sheets w hich is heated and stamped, followed by vaccum or pressure forming.

Injection molding machine

Injection molding cont., Generally discontinous fibrous reinforcement is used, which increase of melt viscosity. Short fiber reinforced thermoplastic resin composites can also be produced by a method called Reinforced Reaction Injection Molding [RRIM]-extension of Reaction injection molding [RIM].

Reaction injection moulding Reaction moulding reactive (RIM) injection Two are ingredients pumped at high speeds and pressures into a mixing head and injected into a mold cavity where curing occur and due solidific ation to chemical reaction.

Reinforced reaction injection molding Reinforced reaction injection moulding (RRIM) - similar to RIM but includes rein forcing fibers, typically glass fibers, in the mixture . Advantages: similar to RIM (e.g., no heat energy required, lower cost mold), wit h the added benefit of fiber reinforcement. Products: auto body, truck cab applications for bumpers, fenders, and other body parts

RIM Reaction injection molding (RIM) Two reactive ingredients are pumped at high spe eds and pressures into a mixing head and injected into a mold cavity where curing and solidification occur due to chemical reaction.

RIM cont.,

Advantages Since the mixing load is self-cleaning, no solvent flush is required, as it is in low-pressure molding. Since there is no mechanical mixing, outputs are higher and foster reacting uret hane mixes can be used. Since reaction time is turn reducing cycle time uces air entrapment part ostly molds can be used, faster, mold residence time is reduced, in (up to 75%). Since high-pressure impingement mixing red appearance is improved. Mold pressure is low and less c compared to injection molding.

RRIM Reinforced reaction injection molding (RRIM) - similar to RIM but includes reinf orcing fibers, typically glass fibers, in the mixture . Advantages: similar to RIM (e.g., no heat energy required, lower cost mold), wit h the added benefit of fiber reinforcement. Products: auto body, truck cab applications for bumpers, fenders, and other body parts

Polymer Processing Forming Processes for Thermosetting matrix composites: Hand layup and sprayup techniques. Filament winding. Pultrusion. Resin transfer moulding. Autoclave moulding. Forming Processes for Thermoplastic matrix composites: Injection moulding. Film stacking. Diaphragm forming. Thermoplastic tape laying.

Film stacking Stack of laminate consists of fibers, impregnated with insufficient thermoplasti c matrix, and polymer films of complementary weight to give the desired fiber vo lume fraction in the end product. These are then consolidated by simultaneous ap plication of heat and pressure. Generally, a pressure of 6-12 MPa, a temperature between 275 and 350 C, and dwell times of up to 30 mins are appropriate for ther moplastics such as polysulfones and polyetheretherketone (PEEK).

Film stacking Laminate of thermoplastics matrix containing fibers with a very low resin content (~15 w/o) are used in this process. A low resin content is used because these are very boardy materials. The laminat e are stacked alternatively with thin films of pure polymer matrix materials.

Film stacking

Film stacking cont., stack of laminate consists of fibers impregnated with insufficient matrix and polymer films of complementary weight to give the desired fiber volume fraction in the end product. These are then consolidated by simultaneous application of heat and pressure.

Film stacking cont., A good quality laminate must be void-free. This implies that there must be suffi cient flow of the thermoplastic matrix between layers as well as within individual tows. Generally, a pressure of 6-12 Mpa, a temperature between 275 and 350 C, and dwell times of up to 30 mins are appropriate for therm oplastics such as polysulfones and polyetheretherketone (PEEK).

Film stacking cont., Heat and pressure are applied simultaneously to these drapeable sheets to produce a composite part. Hot forming of laminated sheets of thermoplastics containing fibers is common, wi th stamping and rolling being frequently used methods.

DIAPHRAGM FORMING This process involves the sandwiching of freely floating thermoplastics prepreg layers between two diaphragm . The air between the diaphragms is evacuated and thermoplastic laminate is heated above the melting point of the matrix. Pressure is applied to one side, which deforms the diaphragm and makes them take the shape of the mold. The laminate layers are freely floating and very flexible above the melting poin t of the matrix, thus they readily conform to the mold shape.

Diaphragm forming cont.,

Diaphragm forming cont.,

DIAPHRAGM FORMING cont., After the completion of the forming process, the mold is cooled, the diaphragms are stripped off, and the composite is obtained The diaphragms are the key to the forming process, and their stiffness is a very critical parameter. For very complex shapes requiring high molding pressures, stiff diaphragm are needed. At high pressures, a significant transverse squeezing flow can result, and this can produce undesirable thickness variations in the final composite.

DIAPHRAGM FORMING cont., ADVANTAGES: Components with double curvatures can be formed. Compliant diaphragm do the job for simple components.

 DIAPHRAGM FORMING This process involves the sandwiching of freely floating thermoplastic prepreg layers between two diaphragms . The air between the diaphragms is evacuated and thermoplastic laminate is heated above the melting point of the matrix.

DIAPHRAGM FORMING Pressure is applied to one side, which deforms the diaphragm and makes them take the shape of the mold. The laminate layers are freely floating and very flexible above the melting poin t of the matrix, thus they readily conform to the mold shape.

DIAPHRAGM FORMING After the completion of the forming process, the mold is cooled, the diaphragms are stripped off, and the composite is obtained. The diaphragms are the key to the forming process, and their stiffness is a very critical parameter. For very complex shapes requiring high m olding pressures, stiff diaphragm are needed. At high pressures, a significant transverse squeezing flow can result, and this can produce undesirable thickness variations in the final composite.

DIAPHRAGM FORMING ADVANTAGES: Components with double curvatures can be formed. Compliant diaphragm do the job for simple components.

Polymer Processing Forming Processes for Thermosetting matrix composites: Hand layup and sprayup techniques. Filament winding. Pultrusion. Resin transfer moulding. Autoclave moulding. Forming Processes for Thermoplastic matrix composites: Injection moulding. Film stacking. Diaphragm forming. Thermoplastic tape laying.

Thermoplastic tape laying (Automated Layup) In this method layers of prepreg (reinforcing phase impregnated by liquid resin) tape are applied on the mold surface by a tape application robot. Cost is about half of hand lay-up. used for thermoset or thermoplastic matrix. limited to fla t or low curvature surfaces. Extensively used for products such as airframe comp onents, bodies of boats, truck ,tanks, swimming pools and ducts.

Automated tape-laying machine (photo courtesy of Cincinnati Milacron). Automated tape-laying machines operate by dispensing a prepreg tape onto an open mold following a programmed path . Typical machine consists of overhead gantry to which the dispensing head is attached. The gantry permits x-y-z travel of the head, for positioning and following a defined continuous path.

Thermoplastic tape laying Cut and lay the ply or prepreg under computer control and without tension, may allow reentrant shapes to be made. Cost is about half of hand lay-up Extensi vely used for products such as airframe components, boats, truck ,bodies, tanks, swimming pools, and ducts.

Automated Tape-Laying Machines Automated tape-laying machines operate by dispensing a prepreg tape onto an open mold following a programmed path Typical machine consists of overhead gantry to which the dispensing head is attached The gantry permits x-y-z travel of the he ad, for positioning and following a defined continuous path 2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/ e

Figure 15.6 Automated tape-laying machine (photo courtesy of Cincinnati Milacron ). 2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/ e

PREPREG PRODUCTION PROCESSES

Prepreg is the composite industry's term for continuous fiber reinforcement. Pre-i mpregnated with a polymer resin that is only partially cured.

Prepreg is delivered in tape form to the manufacturer ,then molds and fully cure s the product without having to add any resin. This is the composite form most w idely used for structural applications.

PREPREG PRODUCTION PROCESSES cont.,

The final prepreg product is a thin tape consisting of continuous and aligned fi bers embedded in a partially cured resin. Prepared for packaging by winding onto a cardboard core. Typical tape thicknesses range between 0.08 and 0.25 mm Tape widths range between 25 and 1525 mm. Resin content lies between about 35 and 45 vol%

PREPREG PRODUCTION PROCESSES cont.,

The prepreg is stored at 0 C (32 F) or lower because matrix undergoes curing reacti ons at room temperature. Also the time at room temperature must be minimized. Li fe time is about 6 months if properly handled. Both thermoplastic and thermosett ing resins are utilized carbon, glass, and aramid fibers are the common reinforc ements. Actual fabrication begins with the lay-up. Normally a number of plies ar e laid up to provide the desired thickness. The lay-up can be by hand or automat ed.

APPLICATIONS OF PMCs Polymer composites are used to make very light bicycles that are faster and easi er to handle than standard ones, fishing boats that are resistant to corrosive s eawater and lightweight turbine blades that generate wind power efficiently. New commercial aircraft also contain more composites than their predecessors. A 555-passenger plane recently built by Airbus, for example, consi sts of 25 percent composite material, while Boeing is designing a new jumbo airc raft that is planned to be more than half polymer composites. Polymer Matrix Com posites (PMCs) are used for manufacturing: secondary load-bearing aerospace stru ctures, boat bodies, canoes, kayaks, automotive parts, radio controlled vehicles , sport goods (golf clubs, skis, tennis racquets), fishing rods, bullet-proof ve sts and other armor parts, brake and clutch linings.

ADVANTAGES: Lightweight Strong No rotting or rusting Easy to maintain. Glass fiber boat

SPORTING GOODS REASONS FOR USING PMC FOR SPORTING GOODS High strength and stiffness; Low wei ; Resistance to aggressive marine, water, and high UV environments; Monolithic a nd seamless construction without leakage and assembly problems; Durability and e ase of maintenance and repair; High energy absorption; Design flexibility for sp ecific requirements; Good dielectric, absence of magnetic properties and low the rmal conductivity.

GOLF CLUB

GOLF CLUB Carbon, Kevlar, glass and ultra high molecular polyethylene fibres are used eith er individually or in hybrid format to satisfy different requirements. Virtually all golf clubs are currently manufactured using the filament winding process. F ilament wound clubs provide superior performance at low weight and cost compared to rollwrapped clubs.

Golf club ADVANTAGES: High bending and torsional stiffness and strength, Lightweight, opti mal weight distribution and damping effects. Polymer composites provide designer s and manufacturers with great flexibility in design and fabrication techniques.

BICYCLE

BICYCLE Polymer composites are now used in almost every part of the bicycle including bi cycle frame, handle bars, seat post, front fork, wheels and pedals. Even the cha in can be replaced using a rubber composite as seen on some bikes and motorcycle s e.g. BMW.

BICYCLE Continuous carbon, aramid, glass, boron and ultrahighmolecular-weight polyethyle ne fibres are used to reinforce different thermosetting matrices.

Tour de France bicycle phenomenal success of carbon fibre frames in the Tour de France Bicycle Race in 1989 and 1990 had a significant impact on the acceptance and popularity of such composites in the bicycle industry.

DELTA 7 ARANTIX BICYCLE

BOW & ARROW

Bow & arrows Made of carbon fibre reinforced epoxy. Provides thinner and lighter construction consequently reducing drag forces, facilitating the aiming accuracy, increasing the velocity and improving the distance the arrows can travel.

SKIS

SKIS Glass and carbon fibre reinforced epoxy are widely used for skis and ski poles b ecause they have exhibited extremely high bending and tensional stiffness and st rength as well as excellent damping characteristics.

FISHING POLES

FISHING POLES Glass, carbon and Kevlar fibres reinforced epoxies are used for producing fishin g poles all over the world. Carbon fibre reinforced epoxy fishing poles are ligh ter than bamboo and possess a better sensitivity and "feel". Because vibrations are rapidly dampened and waves in the line are minimized.

Fishing poles The poles are mainly made using a balanced wrap pattern. This technique puts a n umber of fibres in one direction and an equal number in the opposite direction s o that the rod is balanced cylindrically and longitudinally. Such poles respond more quickly and steadily because they return to their original orientations wit h a more dynamic forward thrust than conventional poles.

Fishing poles The poles are made mostly by pultrusion technique thus significantly booting the production of fishing poles and allowing high degrees of automation and product ivity. ADVANTAGES: stiffness, strength, foldable features and aesthetic effects.

TENNIS RACKET Tennis racquets once made from wood, then aluminum, are now typically made from graphite or graphite-based composites, and improved composites based on fibergla ss, Kevlar (aramid fibers). The composite fibers used in tennis racquets are ang led specifically to reduce bending and twisting and to improve stability.

TENNIS RACKET ADVANTAGE: Lighter weight Higher strength Enables to swing graphite based tennis rackets with tighter strings at a higher velocity, thereby greatly increasing t he speed of the tennis ball.

RADOME a housing for a radar antenna; transparent to radio waves. A radome is a structu ral, weatherproof enclosure that protects a microwave or radar antenna.

RADOME

RADOME designed and manufactured by MFG (molded fiber glass) Galileo. manufactured usin g composite materials such as fiberglass, quartz, and aramid fibers held togethe r with polyester, epoxy, and other resins.

AEROSPACE INDUSTRY

Boeing 7E7 - 787

Boeing 787 First of its kind to use composite structures for wings, fuselage, and nose cone Increased resistance to hoop stress in the fuselage allowing the cabin pressure increases Previous aircraft Boeing 787 - 9000 ft pressure rating - 6000 ft pressure rating Lower altitude pressure = Increased comfort for passengers.

Boeing 787 - Fuselage

Boeing 787 Increased fuselage strength allows for the largest windows available on a commer cial aircraft, which benefits passenger's experience.

Boeing 787 Nose\Cockpit

Limitations of PMC Low maximum working temperature High coefficient of thermal expansion- dimensional instability Sensitivity to radiation and moisture

HELICOPTER ROTOR BLADE

A380 AIRPLANE

AIRCRAFT

COMMERCIAL AIRCRAFT

MILITARY AIRCRAFT

AIRCRAFT COMPOSITE CONTENT

Hoop-wrapped glass fiber composite materials CNG cylinder

Hoop-wrapped glass fiber composite materials CNG cylinder Brand: Modernmed Model: MCNG-2 Origin: china Company: Shanghai Ybo Industries

Hoop-wrapped glass fiber composite materials CNG cylinder Purpose: natural gas transportation Advantage: light weight, hence increased pay load.

Hoop-wrapped glass fiber composite materials CNG cylinder

Hoop-wrapped glass fiber composite materials CNG cylinder

SPECTRA SHIELD

SPECTRA SHIELD

SPECTRA SHIELD

SPECRA SHIELD Spectra Shield is the strongest, lightest, composite ballistic material made toda y! Spectra Shield is ten times stronger than steel !!. Spectra Shield is about 40% lighter than [ Kevlar] .

SPECTRA SHIELD Spectra Shield is a thin, flexible ballistic composite made from layers of unidir ectional fibers held in place by flexible resins. These fibers are arranged so they cross each other at 0 and 90 degree angles Bot h fiber and resin layers are sealed between two thin sheets of polyethylene film .

Anti-rifle plate NIJ Level III+ (Plus) Multi-Hit SAPI Tactical, anti-Rifle Plates made of modern Ceramic Composite with bonded Dyneema, Spectra Shield, Twaron or Kevlar Ballistic fi ber backing are amongst the lightest and thinnest plates in the world against ri fle threats of up to 7.62 X 51 mm FMJ NATO BALL from military machine guns as we ll as the 5.56 X 45 mm, SS 109, US/NATO M855 or Swedish 10B or 5B NOTOX ammuniti on.

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