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Polymermatrixcomposites 110526080726 Phpapp01
Polymermatrixcomposites 110526080726 Phpapp01
fibre/polymer
Applications.
interface.
Mechanical
properties
Fracture.
Matrices
Polymer Matrix
Composites
(PMC)
Thermoset
Thermoplast
ic
Metal Matrix
Composites
MMC)
Rubber
Ceramic Matrix
Composites
(CMC)
What is a polymer?
Poly
many
mer
repeat unit
Examples of polymers:
repeat
unit
repeat
unit
H H H H H H
C C C C C C
H H H H H H
H H H H H H
C C C C C C
H Cl H Cl H Cl
Polyethylene (PE)
repeat
unit
H
C
H
H H
C C
CH3 H
H H
C C
CH3 H
Polypropylene (PP)
H
C
CH3
Polymer(Matrix)
Composite (Matrix + Reinforcement)
Discontinuous phase - Reinforcement
Continuous phase
- Matrix
Reinforcements
Principal load bearing member.
Matrix
provides a medium for binding and holding the reinforcements
together into a solid.
protects the reinforcement from environmental degradation.
serves to transfer load from one insert (fibre, flake or particles) to
the other.
Provides finish, colour, texture, durability and other functional
properties.
Classification of Polymers
Linear polymer - Any polymer in which molecules are in
the form of chains.
Thermoplastic polymers - Linear or branched polymers in
which chains of molecules are not interconnected to one
another.
Thermosetting polymers - Polymers that are heavily
cross-linked to produce a strong three dimensional
network structure.
Elastomers - These are polymers (thermoplastics or
lightly cross-linked thermosets) that have an elastic
deformation > 200%.
Molecular chain
configurations:
a.
b.
c.
d.
Linear
Branched
Crossed linked
Ladder
Fibers in PMCs
Polymerisation:
This is the process of joining monomers into gaint chain like molecules.
Methods of Polymerisation:
Condensation polymerisation
Addition polymerisation
Thermosets
Thermoset materials are usually liquid or malleable prior to curing,
and designed 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 relatively
insoluble and infusible substance.
The cross-links form during the polymerisation of the liquid resin and
hardener, so the structure is almost always amorphous.
Thermosets
Epoxy:
Epoxy is a polymer that contain an epoxide group in its chemical structure.
Example: DGEBA (Diglcidyl Ether of Bisphenol A )
Charecteristics of Epoxy:
Better Moisture Resistence
Low shrinkage
Good adhersion with Reinforcement
Polyester:
A condensation reaction between a glycol and an unsaturated dibasic
acid results in polyster. This contains a double bond C=C between its
carbon atoms.
Example: poly ethylene terephthalate (PET).
Charecteristics of Polyester:
Cheap
Resistance to variety of chemicals
Adequate moisture resistance
Thermoplastics
In thermoplastic polymer, individual molecules are linear in structure with
no chemical linking between them.
Thermoplastics (80%)
Can be recycled.
Types of Thermoplastics
Functions of Matrix
Distributes the loads evenly between fibres so that all fibres are subjected
to the same amount of strain.
Limitations of PMC
Polymer Processing
Forming Processes for Thermosetting matrix composites:
Injection moulding.
Film stacking.
Diaphragm forming.
Thermoplastic tape laying.
Hand Layup
Fiberglass reinforcement is
placed in the mold.
Hand Layup
Hand Layup
Advantages:
Widely used.
Low tooling cost.
Custom shape.
Larger and complex items can
be produced.
Potential Problems:
Labour intensive.
Low-volume process.
Styrene emission.
Quality control is entirely
dependent on the skill of
labourers.
SPRAYUP
In Sprayup process liquid resin matrix and chopped reinforcing fibers are
sprayed by two separate sprays onto the mold surface.
The fibers are chopped 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 costs 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, etc
In both the cases the deposited layers are densified with rollers.
Design Flexibility.
Labor Intensive.
PREPREG
PREPREG PROCESS
Manufacturing begins by
collimating a series of
spool-wound continuous
fiber tows.
Tows are then
sandwiched and 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 prepreg product is a thin tape consisting of continuous and aligned fibers
embedded in a partially cured resin.
PREPREG
PREPREG
Both thermoplastic and thermosetting resins are utilized: carbon, glass, and
aramid fibers are the common reinforcements.
Actual fabrication begins with the lay-up. Normally a number of plies are
laid up to provide the desired thickness.
Filament Winding
Filament Winding method involves a continuous filament of
reinforcing material wound onto a rotating mandrel in layers at
different layers. If a liquid thermosetting resin is applied on the
filament prior to winding the, process 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 may be used.
44
Filament Winding
Filament Winding
Demolding
To remove the mandrel, the ends of the parts are cut off when appropriate, or a collapsible
mandrel (e.g., low melt temperature alloys ) is used.
Curing in done in an Autoclave for thermoset resins (polyester, epoxy, phenolic, silicone) and
some thermoplastics (PEEK)
Fibers are E-glass, S-glass, carbon fiber and aramids (toughness and lightweight) .
Inflatable mandrels can also be used to produce parts that are designed for high pressure
applications, or parts that need a liner, and they can be easily removed.
Advantages
Good for wide variety of part sizes
Parts can be made with strength in several different directions
Very low scrap rate
Non-cyclindrical parts can be formed after winding
Flexible mandrels can be left in as tank liners
Reinforcement panels, and fittings can be inserted during winding
Due to high hoop stress, parts with high pressure ratings can be made
Disadvantages
Viscosity and pot life of resin must be carefully chosen
NC programming can be difficult
Some shapes can't be made with filament winding
Factors such as filament tension must be controlled
46
Filament Winding
drive shafts
Entec the worlds largest five-axis filament winding machine for wind
turbine blades
length 45.7 m, diameter 8.2 m, weight > 36 tonnes.
Filament winding
helical:
polar:
Kevlar component
Pultrusion
Description:
Pultrusion is a process where composite parts are manufactured by
pulling layers of fibres/fabrics, impregnated with resin, through a heated
die, thus forming the desired cross-sectional shape with no part length
limitation.
Pultrusion
Pultrusion
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.
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
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 (up to 80% of roving reinforcement, up
to 50% of mixed mat + roving reinforcement).
Pultrusion is used for fabrication of Fiber glass and Carbon fiber
reinforced polymer composites and Kevlar (aramid) fiber reinforced
polymers.
Pultrusion
Manufacturing
Fibers are brought together
over rollers, dipped in resin
and drawn through a heated
die. A continuous cross
section composite part
emerges on the other side.
Pultrusion
Design
Hollow parts can be made using a mandrel that extends out the exit side of
the die.
Variable cross section parts are possible using dies with sliding parts.
Two main types of dies are used, fixed and floating. Fixed dies can
generate large forces to wet fiber. Floating dies require an external power
source to create the hydraulic forces in the resin. Multiple dies are used
when curing is to be done by the heated dies.
63
Materials
Most fibers are used (carbon, glass, aramids) and Resins must be fast curing
because 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 belts/chains can be used to pull the part through. The best designs
allow for continuous 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 parts have good axial properties.
Advantages
good material usage compared to layup
high throughput and higher resin contents are possible
Disadvantages
part cross section should be uniform.
Fiber 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 die does not conform well to the fibers being pulled
quick curing systems decrease strength
65
Pultrusion
Advantages:
Minimal kinking of
fibres/fabrics
Potential Problems:
Improper fibre wet-out
Fibre breakage
Rapid processing
Inadequate cure
Die jamming
Pultrusion -characteristics
seek uniform thickness in order to achieve uniform cooling and hence minimise
residual stress.
hollow profiles require a cantilevered mandrel to enter the die from the fibre-feed
end.
continuous constant cross-section profile
normally thermoset (thermoplastic possible)
impregnate with resin
pull through a heated die
resin shrinkage reduces friction in the die
polyester easier to process than epoxy
tension control as in filament winding
post-die, profile air-cooled before gripped
hand-over-hand hydraulic clamps
conveyor belt/caterpillar track systems.
moving cut-off machine ("flying cutter"). The solid laminate will be cut to the
desired length
Inside the metal die, precise temperature control activates the curing of the
thermoset resin.
Shapes such as rods, channels, angle and flat stocks can be easily
produced.
Profiles as wide as 1.25 m with more than 60% fiber volume fraction
can be made routinely.
Pultrusion -applications
Pultrusion Applications
http://
In the RTM process, dry (i.e. non-impregnated ) reinforcement is preshaped and oriented 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 injected
The part is cured in mold.
The mold is opened and part is removed from mold.
RTM
Transfer Molding (Resin Transfer Molding) 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 picture below illustrates the Transfer Molding Process.
The method uses a split mold and a third plate equipped with a plunger
mounted in a hydraulic press.
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.
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.
RTM
Transfer Molding process involves the following steps:
Advantages of RTM
Disadvantages of RTM
Potential Problems:
Kinking of fibres
RTM Products:
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 pressure.
The molded part is first placed into a plastic bag, from which air is
exhausted by a vacuum pump. This operation removes air inclusions
and volatile products 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 method is relatively expensive and is used for
manufacturing high quality aerospace products.
Autoclave moulding
Autoclave
An oven that allows for high pressures to be used.
Composites cure under heat and pressure provides a superior part because
the voids are reduced due to the pressure.
Process
The part is placed in the pressure vessel, and heated, pressure is applied
simultaneously.
Vacuum bagging can be used in an autoclave.
Thermoset composites are crosslinked.
Thermoplastics are melted.
Advantages
The pressure helps bond composite layers, and remove more voids in the
matrix.
Very large parts can be made with high fiber loadings.
Properties are improved.
Many different parts can be cured at the same time.
Disadvantages
Autoclaves are expensive
Copyright Joseph Greene 2001
82
a)
b)
Autoclave Moluding
Injection moulding
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 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.
A principal scheme of an Injection Molding Machine is shown in the
picture below.
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
The clamping unit: Its role is to open and close the mold, and hold
the mold tightly to avoid flash during the filling and holding.
Clamping can be mechanical or hydraulic.
Mold cavity
Cooling system
(for thermoplastics)
Ejector system
INJECTION MOLDING
Screw-back: At the same time, the screw retracts and turns, feeding the
next shot in towards the front
It is used for numerous products, ranging from boat hulls and lawn chairs,
to bottle cups. Car parts, TV and computer housings are injection molded.
Reaction
injection
moulding
reactive
(RIM)
Two
ingredients
are
pressures
into
and
due
reaction.
solidification
to
chemical
Film stacking
DIAPHRAGM FORMING
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
point 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.
DIAPHRAGM FORMING
ADVANTAGES:
Interfacial bonding
Good bonding (adhesion) between matrix phase and dispersed
phase provides transfer of load, applied to the material to the
dispersed phase via the interface. Adhesion is necessary for
achieving high level of mechanical properties of the composite.
There are three forms of interface between the two phases:
Direct bonding with no intermediate layer. In this case adhesion
(wetting) is provided by either covalent bonding or van der
Waals force.
Intermediate layer (inter-phase) is in form of solid solution of the
matrix and dispersed phases constituents.
Intermediate layer is in form of a third bonding phase (adhesive).
The Interface
There is always an interface between constituent phases in a composite
material.
For the composite to operate effectively, the phases must bond where they join
at the interface.
Reinforcement-Matrix Interface
The load acting on the matrix has to be transferred to the reinforcement
via. Interface.
The reinforcement must be strongly bonded to the matrix if high
stiffness and strength are desired in the composite materials
A weak interface results in low stiffness and strength but high resistance
to fracture.
A strong interface produces high stiffness and strength but often low
resistance to fracture, i.e. brittle behavior
2 types of failure at interface
1) Adhesive failure - failure occur at interface
2) Cohesive failure failure occur close to the interface (either at the fiber or
matrix)
Interfacial bonding
Once the matrix has wet the reinforcement, bonding will occur.
For a given system, more than one bonding mechanism may exist at
the same time.
The bondings may change during various production stages or
during services.
Mechanical Bonding
It is a simple mechanical keying or
interlocking effect between the
fiber-matrix phases.
When the matrix shrinks radially on
cooling over the reinforcement
leads to a griping action of the
matrix on the fiber.
Physical Bonding
Chemical bonding
Dissolution Bonding: This bonding is of short range and occurs at an
electronic scale. This type of bonding is hindered by the presence of
impurities on the fiber surface and also gas or air bubbles at the
interface.
Reaction Bonding: This bonding is due to the transport of the
molecules, atoms or ions which diffuse to the interface.
Interphase
Another Interphase
Interphase consisting of a solution of primary and
secondary phases
APPLICATIONS OF PMCs
Polymer composites are used to make very light bicycles that are
faster and easier to handle than standard ones, fishing boats that
are resistant to corrosive seawater 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, consists of 25 percent
composite material, while Boeing is designing a new jumbo aircraft
that is planned to be more than half polymer composites.