3 Met416 CM Module 3

02-03-2023
MET416 – COMPOSITE
MATERIALS
Module 3
Polymer Matrix Composites (PMC)
Dr. Sreekanth. M. P 1
Introduction
Source:
https://www.slideshare.
net/BKLR/polymer-
matrix-composites
1
02-03-2023
Introduction
Source:
net/BKLR/polymer-
matrix-composites
• Polymer Matrix Composite (PMC) is the material Introduction

consisting of a polymer (resin) matrix combined
with a fibrous reinforcing dispersed phase.
• Polymer Matrix Composites are very popular due to
their low cost and simple fabrication methods.
• PMCs have High tensile strength; High stiffness;
High Fracture Toughness; Good abrasion
resistance; Good puncture resistance; Good
corrosion resistance; Low cost.
• The main disadvantages of Polymer Matrix
Composites (PMC) are:
Low thermal resistance;
Source:
High coefficient of thermal expansion. https://www.substech.c
om/dokuwiki/doku.php?i
d=polymer_matrix_com
posites_introduction
2
02-03-2023
Introduction
Source:
net/BKLR/polymer-
matrix-composites
Introduction
Source:
net/BKLR/polymer-
matrix-composites
3
02-03-2023
Introduction
Source: https://www.slideshare.net/BKLR/polymer-matrix-composites
Introduction
Source:
http://frontdesk.co.in/co
nstruction-
materials/plastics/
4
02-03-2023
Thermoplastic
Source:
https://www.slideshare.net/BKLR
/polymer-matrix-composites &
http://frontdesk.co.in/construction
-materials/plastics/
General properties:
Low melting point
Softer
Flexible Typical uses:
Bottles
Food wrappers
Toys
Thermoplastic
Source:
net/BKLR/polymer-
matrix-composites
5
02-03-2023
• Polyethylene (or polythene): Flexible use in Thermoplastic

packaging, electrical insulation, milk and
water bottles.
• Polypropylene: Stiff and hard and coarser
than the polyethylene. Low density. Use in
carpet fibers, automotive bumpers,
microwave containers, prosthetics.
• Polyvinyl chloride (PVC): Rigid ,Tough and
elastic. Use in electrical cables cover, credit
cards, car instrument panels.
• Polystyrene: Solid and glass clear. Use in
disposable spoons, forks, etc. Source:
nstruction-
materials/plastics/
Thermoplastic
• Acrylics (PMMA: Polymethyl Methacrylate):
Glass clear and somewhat brittle. Use in
paints, plexiglass etc.
• Polyamide (Nylon): High density polythene.
Use in textiles and fabrics, gears, bushing
and washers, bearings.
• PET (Polyethylene Terephthalate): Use in
bottles for acidic foods like juices and food
trays.
• PTFE (Polytetrafluoroethylene): Use in
non-stick coating, raincoats, dental floss. Source:
nstruction-
materials/plastics/
6
02-03-2023
Thermosets
Source:
net/BKLR/polymer-
matrix-composites
Thermosets
Source:
net/BKLR/polymer-
matrix-composites
7
02-03-2023
Thermosets
Source:
net/BKLR/polymer-
matrix-composites
• General properties: more durable, harder, Thermosets

tough, light.
• Typical uses: automobile parts, construction
materials.
Examples:
• Malemine formaldehyde (Formica) use in laminates
• Phenolics (Bakelite): bottle caps, bonding plywood,
glues.
• Unsaturated Polyesters: lacquers, varnishes, boat
hulls, furniture.
• Epoxies and Resins: glues, coating of electrical
circuits,
• composites: fiberglass in helicopter blades, boats Source:
nstruction-
materials/plastics/
8
02-03-2023
• General properties: these are thermosets, and Elastomers

have rubber-like properties.
• Typical uses: medical masks, gloves, rubber-
substitutes
Types of Rubber:
• Natural rubber: It is natural product form rubber

tree. The milk form rubber trees called as latex is
collected at rubber plantations.
• Synthetic rubbers: This is a polymer and it is
manufactured by chemical process of
polymerization. Source:
nstruction-
materials/plastics/
Synthetic rubber examples Elastomers

• Butadiene Rubber
• Butyl Rubber
• Chloroprene Rubber
• Ethylene-propylene Rubber
• Isoprene Rubber
• Nitrile Rubber
• Polyurethanes : mattress, cushion, insulation, toys
• Silicones: surgical gloves, applications in joint
seals
• Styrene – Butadiene Rubber (SBR) :
• Thermoplastic Elastomers Source:
nstruction-
materials/plastics/
9
02-03-2023
Comparison
of Polymers
Source:
net/BKLR/polymer-
matrix-composites
Comparison
of Polymers
Source:
net/BKLR/polymer-
matrix-composites
10
02-03-2023
PMC
Source: https://www.slideshare.net/BKLR/polymer-matrix-composites & https://www.sciencedirect.com/science/article/pii/B9780857096838500094
PMC
Source: https://www.slideshare.net/BKLR/polymer-matrix-composites
11
02-03-2023
Characteristics of Polymers: PMC

• Low Density.
• Low coefficient of friction.
• Good corrosion resistance.
• Good mould ability.
• Excellent surface finish can be obtained.
• Can be produced with close dimensional tolerances.
• Economical.
• Poor tensile strength.
• Low mechanical properties.
• Poor temperature resistance.
• Can be produced transparent or in different colors.
Source:
https://slideplayer.com/
slide/6019693/
PMC
Properties of Polymers:
• Reflective
• Impact resistant
• Tough
• Brittle
• Translucent
• Malleable
• Soft
• Elastic
Source:
slide/6019693/
12
02-03-2023
PMC
Source:
https://www.yout
ube.com/watch?
v=rpFnotLGlvo
MET416 – COMPOSITE
MATERIALS
Module 3
Processing of Polymer Matrix Composites
(PMC)
13
02-03-2023
Processing
of PMC
Source:
https://www.hindawi.co
m/journals/jnm/2022/8
605099/
Hand
Lay – up
Method
Source:
https://www.eppcompo
sites.com/hand-layup-
process.html
14
02-03-2023
• Hand lay-up technique is the simplest method of Hand

composite processing. The infrastructural Lay – up
requirement for this method is also minimal. The
processing steps are quite simple. Method
• First of all, a release gel is sprayed on the mold
surface to avoid the sticking of polymer to the
surface.
• Reinforcement in the form of woven mats or

chopped strand mats are cut as per the mold size
and placed at the surface of mold after. Source:
process.html
Hand
• Then thermosetting polymer in liquid form is mixed Lay – up
thoroughly in suitable proportion with a prescribed
hardener (curing agent) and poured onto the Method
surface of mat already placed in the mold.
• The polymer is uniformly spread with the help of

brush. Second layer of mat is then placed on the
polymer surface and a roller is moved with a mild
pressure on the mat-polymer layer to remove any
air trapped as well as the excess polymer present.
Source:
process.html
15
02-03-2023
• The process is repeated for each layer of polymer Hand

and mat, till the required layers are stacked. Lay – up
• After curing either at room temperature or at some Method
specific temperature, mold is opened and the
developed composite part is taken out and further
processed.
• Capital and infrastructural requirement is less as

compared to other methods. Production rate is less
and high volume fraction of reinforcement is difficult
to achieve in the processed composites. Source:
process.html
Hand
Lay – up
Method
Source:
https://slideplayer.com
/slide/4452286/
16
02-03-2023
Spray
Lay – up
Method
Source:
sites.com/spray-layup-
process.html
• The spray lay-up technique can be said to be an Spray

extension of the hand lay-up method. In this Lay – up
technique, a spray gun is used to spray
pressurized resin and reinforcement which is in the
Method
form of chopped fibers.
• Generally, glass roving is used as a reinforcement

which passes through spray gun where it is
chopped with a chopper gun.
• Matrix material and reinforcement may be sprayed

simultaneously or separately one after one. Source:
process.html
17
02-03-2023
Spray
• Spray release gel is applied on to the mold surface to
facilitate the easy removal of component from the mold. Lay – up
• A roller is rolled over the sprayed material to remove air
Method
trapped into the lay-ups. After spraying fiber and resin to
required thickness, curing of the product is done either
at room temperature or at elevated temperature.
• After curing, mold is opened and the developed

composite part is taken out and further processed
further. The time of curing depends on type of polymer
used for composite processing.
Source:
process.html
Spray
Lay – up
Method
Source:
slide/4452286/
18
02-03-2023
Compression
Moulding
Source:
process.html
Compression Moulding
• It is a Closed Mould process in which a molding charge is squeezed

into a preheated mold taking a shape of the mold cavity and
performing curing (cross-linking) due to heat and pressure applied to
the material.
• The method uses a split mold mounted in a hydraulic press
• Compression Molding process involves the following steps:
• A pre-weighed amount of a polymer (commonly thermosetting resin)
mixed with chopped reinforcing fibers, hardening agent, anti-adhesive
agent and pigment (charge) is placed into the lower half of the mold.
Source: https://www.substech.com/dokuwiki/doku.php?id=closed_mold_fabrication_of_polymer_matrix_composites
19
02-03-2023
• The charge may be in form of powders, pellets, putty-like masses or

pre-formed sheets.
• The charge is usually preheated prior to placement into the mold.
Preheated polymer becomes softer resulting in shortening the molding
cycle time.
• The upper half of the mold moves downwards, pressing on the charge
and forcing it to fill the mold cavity.
• The mold, equipped with a heating system, provides curing (cross-
linking) of the polymer matrix (if thermosetting resin is processed).
• The mold is opened and the part is removed from it by means of the
ejector pin.
• Compression Moulding cycle time is about 1-6 min, which is longer

than Injection Molding cycle.
• The method is suitable for mass production of flat or moderately

curved parts.
20
02-03-2023
Compression
Moulding
Source:
https://www.silgancls.com/co
mpression-vs-compression-
plastic-closures/
Injection
Moulding
Source:
process.html
21
02-03-2023
Injection Moulding
• It is a Closed Mould process in which molten polymer (commonly

thermoplastic) mixed with very short reinforcing fibers (10 – 40%) is
forced under high 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.
• The 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.
Injection Moulding
• Screw of injection moulding machine is called reciprocating screw
since it not only rotates but also moves forward and backward
according to the steps of the molding cycle.
• It acts as a ram in the filling step when the molten polymer-fibers
mixture is injected into the mold and then it retracts backward in the
molding step.
• Heating elements, placed over the barrel, soften and melt the polymer.
• The mould is equipped with a cooling system providing controlled
cooling and solidification of the material.
• 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.
22
02-03-2023
Injection Moulding
• Injection Molding is used mainly 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 heated barrel.
• Injection Molding is highly productive method providing high accuracy
and control of shape of the manufactured parts. The method is
profitable in mass production of large number of identical parts.
• One of the disadvantages of the method is limited length of fibers
decreasing their reinforcing effect.
Injection
Moulding
Source:
https://www.silgancls.com/co
mpression-vs-compression-
plastic-closures/
23
02-03-2023
Transfer
Moulding
Source:
process.html
Transfer Moulding
• It is a Closed Mold process in which a pre-weighed amount of a
polymer is preheated in a separate chamber (transfer pot) and 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 heat and pressure applied to the material.
• The method is used primarily for molding Polymer Composites with
thermosetting resin matrices, but some thermoplastic parts may also
be produced by Transfer Molding.
• The method combines features of both Compression Molding -
hydraulic pressing, the same molding materials (thermosets) and
Injection Molding – ram (plunger), filling the mold through a sprue.
24
02-03-2023
Transfer Moulding
• 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
pre-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).
Transfer Moulding
• 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 channels is
removed. Scrap of thermosetting polymers is not recyclable.
• Transfer Molding cycle time is shorter than Compression Molding cycle but
longer than Injection Molding cycle.
• The method is capable to produce very large parts (car body shell), more
complicated than Compression Molding, but not as complicated as Injection
Molding.
25
02-03-2023
Transfer
Moulding
Source:
slide/7590435/
BAG MOULDING PROCESS (PREPREG LAY-UP PROCESS)
• This is a closed mould process and is adopted to make

composites where high reinforcement to resin ratio is required.
• Also certain composite systems like carbon fiber, boron fiber
and silica fiber reinforcements in high molecular polymer resin
will require better compaction and continuous removal of
entrapped air and volatile substances.
• This process also provides smooth and textured finishes on all sides
and is better suited for automation.
• Basically Bag Moulding comprises of three different methods as
under: Vacuum Bag moulding, Pressure Bag moulding, and
Autoclave moulding.
Source: https://www.studocu.com/in/document/pes-university/composite-materials/bag-moulding-process-prof-supriya/17819820
26
02-03-2023
• Prepregs are laminate

composites of fiber sheets
that are impregnated with
polymer resins (plastics)
that have not been fully
cured. Fiber sheets are
often fiberglass, carbon
fiber, or polyaramid (Kevlar).
Materials in this form are
often called B-staged.
Source: https://www.sciencedirect.com/topics/materials-science/prepreg
Source: https://slideplayer.com/slide/4452286/
27
02-03-2023
• If only Vacuum is used with atmospheric pressure, the technique is

called Vacuum Bag Moulding.
• If air at room temperature is used to pressurize then the
technique is referred to as Pressure Bag Moulding.
• If hot gases are used in closed chamber, then the technique is
called as Autoclave Bag Moulding.
• One of the oldest and versatile process for consolidating pre-
impregnated laminates (prepregs). The prepregs are cut to
suitable size & shape, laid up on a mould, covered by a flexible
diaphragm, cured under high pressure and temperature.
• Bagging technique requires considerable skill on the part of the

worker to produce high quality finished product.
• Vacuum bag moulding requires simple instruments and handles
large parts and complex shapes.
• Pressure bag and Autoclave are preferred for curing at higher
pressures and temperatures and for higher level of consolidation .
E.g. Helicopter blades, Helicopter rotor shafts, Instrument panels for
Aircrafts, Truss members for Satellites etc.
• Pressures up to 640 MPa and Temperatures up to 200°C can be
achieved in Autoclave.
• Heated air or steam is used for pressurization.
28
02-03-2023
Vacuum
Bag
Moulding
Atmospheric pressure is used. Air is removed from the mould cavity. The pressure
difference cause the lay – up to fill in the cavity.
Dr. Sreekanth. M. P Source: Composite Materials: Production, Properties, Testing, and Applications – K Srinivasan – 2009 – Narosa Publishing House Pvt. Ltd. 57
Vacuum
Bag
Moulding
Source:
https://slideplayer.com/slide/4452286/
29
02-03-2023
Pressure
Bag
Moulding
Pressure Greater than Atmospheric pressure is used. No Autoclave is used.

Economical. A flexible bag is placed over the lay – up, which is one the mould. Gas
is pumped into the bag. This will compress the lay – up into the mould.
Pressure
Bag
Moulding
Dr. Sreekanth. M. P Source: https://www.slideshare.net/Lahiru_Dilshan/vacuum-bag-forming-and-pressure-bag-forming 60
30
02-03-2023
Autoclave Moulding
An autoclave is a machine used to

carry out industrial and scientific
processes requiring elevated
temperature and pressure in relation
to ambient pressure and/or
temperature
Pressure Greater than Atmospheric pressure is used. Mould and lay – up kept
inside the clave. Gas with high pressure is pumped into the autoclave and above
the lay – up. High pressure gas press the lay – up against the mould.
Autoclave Moulding
Source:
https://www.slideshare.net/Ma
nojK55/autoclave-molding
31
02-03-2023
Pultrusion
Process
Source: http://www.substech.com/dokuwiki/doku.php?id=pultrusion
Pultrusion Process
• Pultrusion is an automated, highly productive process of fabrication

of Polymer Matrix Composites in form of continuous long products of
constant cross-section.
Pultrusion process involves the following operations:
• Reinforcing fibers are pulled from the creels.
• Fiber (roving) creels may be followed by rolled mat or fabric creels.
• Pulling action is controlled by the pulling system.
• Guide plates collect the fibers into a bundle and direct it to the resin
bath.
32
02-03-2023
Pultrusion Process
• Fibers enter the resin 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 squeezed out from fibers and the material is
shaped.
• The preformed fibers pass through the heated die where the final
cross-section dimensions are determined and the resin curing
occurs.
• The cured product is cut on the desired length by the cut-off saw.
Pultrusion Process
Pultrusion process is characterized by the following features:
• High productivity.
• The process parameters are easily controllable.
• Low manual labor component.
• Precise 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.
• Pultrusion is used for fabrication of Fiber glasses, Carbon Fiber
Reinforced Polymer Composites and Kevlar (aramid) fiber reinforced
polymers.
33
02-03-2023
Pultrusion
Process
Source:
https://slideplayer.com/slid
e/10477852/
Filament
Winding
Process
Source: https://www.researchgate.net/figure/FRP-composite-manufacturing-process-of-filament-winding-2_fig2_335601265
34
02-03-2023
Filament Winding Process
• Filament winding is an automated method for creating composite

structures by winding filaments under tension over a rotating
mandrel (tool).
• The fiber placement is guided by a machine with two or more axes
of motion.
• Filament winding a used to manufacture a range of products such as
pipes, pipe joints, drive shafts, pressure vessels, storage tanks etc.
• There are a number of different types of filament winding machine
that are best suited to manufacturing different type of components.
Source: https://www.cadfil.com/filamentwindingprocess.html & https://www.azom.com/article.aspx?ArticleID=352

• The mandrel can be any shape that does not have re – entrant
curvature.
• It is possible to remove the component from the mandrel before it
has cured and use some other means of compaction to produce
reverse curvature if required.
• The fibers may be impregnated with resin before winding (wet
winding), reimpregnated (dry winding) or post impregnated.
• Wet winding has the advantages of using the lowest cost materials
with long storage life and low viscosity.
• The prepreg systems produce parts with more consistent resin
content and can often be wound faster.
Source: https://www.azom.com/article.aspx?ArticleID=352
35
02-03-2023
• Glass fiber is the fiber most frequently used for filament winding,
while carbon and aramid fiber are also used.
• Most high strength critical aerospace structures are produced with
epoxy resins, with either epoxy or cheaper polyester resins being
specified for most other applications.
• The component is normally cured at high temperature.
• Finishing operations such as machining or grinding are not normally
necessary.
Source: https://www.azom.com/article.aspx?ArticleID=352
Filament
Winding
Process
Source:
https://slideplayer.com
/slide/4452286/
36

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02-03-2023

• Polymer Matrix Composite (PMC) is the material Introduction

• Polyethylene (or polythene): Flexible use in Thermoplastic

• General properties: more durable, harder, Thermosets

• General properties: these are thermosets, and Elastomers

• Natural rubber: It is natural product form rubber

Synthetic rubber examples Elastomers

Source: https://www.slideshare.net/BKLR/polymer-matrix-composites & https://www.sciencedirect.com/science/article/pii/B9780857096838500094

Characteristics of Polymers: PMC

• Hand lay-up technique is the simplest method of Hand

• Reinforcement in the form of woven mats or

• The polymer is uniformly spread with the help of

• The process is repeated for each layer of polymer Hand

• Capital and infrastructural requirement is less as

• The spray lay-up technique can be said to be an Spray

• Generally, glass roving is used as a reinforcement

• Matrix material and reinforcement may be sprayed

• After curing, mold is opened and the developed

• It is a Closed Mould process in which a molding charge is squeezed

• The charge may be in form of powders, pellets, putty-like masses or

• Compression Moulding cycle time is about 1-6 min, which is longer

• The method is suitable for mass production of flat or moderately

• It is a Closed Mould process in which molten polymer (commonly

• Injection Molding is used mainly for thermoplastic matrices, but

BAG MOULDING PROCESS (PREPREG LAY-UP PROCESS)

• This is a closed mould process and is adopted to make

BAG MOULDING PROCESS (PREPREG LAY-UP PROCESS)

• Prepregs are laminate

BAG MOULDING PROCESS (PREPREG LAY-UP PROCESS)

BAG MOULDING PROCESS (PREPREG LAY-UP PROCESS)

• If only Vacuum is used with atmospheric pressure, the technique is

BAG MOULDING PROCESS (PREPREG LAY-UP PROCESS)

• Bagging technique requires considerable skill on the part of the

Pressure Greater than Atmospheric pressure is used. No Autoclave is used.

Dr. Sreekanth. M. P Source: https://www.slideshare.net/Lahiru_Dilshan/vacuum-bag-forming-and-pressure-bag-forming 60

An autoclave is a machine used to

• Pultrusion is an automated, highly productive process of fabrication

Filament Winding Process

• Filament winding is an automated method for creating composite

Filament Winding Process

Filament Winding Process

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