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COMPOSITES

A composite is a structural material, which consists of combining two or more constituents. The constituents are combined at a macroscopic level and are not soluble in each other. One constituent is called the reinforcing phase and the one in which it is embedded is called the matrix. The reinforcing phase material may be in the form of fibers, particles, or flakes. The matrix phase materials are generally continuous. Examples of composite systems Concrete reinforced with steel. Plastics reinforced with glass or carbon fibers. Epoxy reinforced with graphite fibers. Examples of naturally found composites Composite Material Matrix Reinforcement Wood Lignin Cellulose fibers Bone Minerals Collagen fibers

Advanced Composites Advanced composites are composite materials, which are traditionally used in the aerospace industries. These composites have high performance reinforcements of a thin diameter in a matrix material such as epoxy and aluminium. Classification of Composites By the geometry of the reinforcement - Particulate - Fiber - Flake By the type of matrix - Polymer - Metal - Ceramic Advantages of using composites over metals Monolithic metals and their alloys cannot always meet the demands of today's advanced technologies. Only by using composite materials one can meet the performance requirements. In many cases using composites is more efficient. For example, in the highly competitive air line market, one is continuously looking for ways to lower the overall mass of the aircraft without decreasing the stiffness and strength of its components. This is possible by replacing conventional metal alloys with composite materials. Even if the composite material costs may be higher, the

reduction in the number of parts in an assembly and the savings in fuel costs make them more profitable.

Other Advantages Improved strength Stiffness Fatigue & Impact resistance Thermal conductivity Corrosion resistance, etc.

Limitations High cost of fabrication. Mechanical characterization of a composite structure is more complex than that of a metal structure. Repair of composites is difficult. Applications of Composites Aircraft Automotive Space shuttle Sporting goods Medical devices Military Marine NANO COMPOSITES Very narrow particles (on the nanometer scale) can also be used, and these give rise to nano composites. The general class of nano composite materials is a fast growing area of research. Significant effort is focused on the ability to obtain control of nano scale structures via innovative synthetic approaches. The properties of nano composite materials depend not only on the properties of their individual parents but also on their morphology and interfacial characteristics. This rapidly expanding field is generating many exciting new materials with novel properties. There is also possibility of new properties, which are unknown in the parent constituent materials. Nano composites promise new applications in many fields such as mechanically reinforced lightweight A low-to-medium-volume contact mold method suitable for making boats, tanks, housings and building panels for prototypes and for other large parts requiring high strength. components, non-linear optics, battery cathodes and ionics, nano-wires, sensors and other systems. Processing of Polymer Matrix Composites Hand Lay-up Process Description A pigmented gel coat is first applied to the mold by spray gun for a high-quality surface. When the gel coat has become tacky, fiberglass reinforcement (usually mat or

Catalysts and accelerators are added to the resin system to allow the resin to cure without external heat. The amounts of catalyst and accelerator are dictated by the working time necessary and overall thickness of the finished part. The laminate may be cored or stiffened with honeycomb, balsa, foam plastic, or other materials to provide weight reduction or flotation. Resin Systems General-purpose, room-temperature curing polyesters which will not drain or sag on vertical surfaces. Also, certain epoxies. Molds Simple, single-cavity, one-piece, either male or female, of any size. (Vacuum bag, pressure bag, or autoclave methods may be used to speed cure, increase glass content, and improve offmold surface finish.) Major Advantages Simplest method offering low-cost tooling, simple processing, and wide range of part size. Design changes are readily made. There is a minimum investment in equipment. With good operator skill, good production rates and consistent quality are obtainable. cloth) is manually placed on the mold. The base resin is applied by pouring, brushing, or spraying. Squeegees or rollers are used to densify the laminate, thoroughly wetting the reinforcement with the resin, and removing entrapped air. Layers of fiberglass mat or woven roving and resin are added for thickness.

SPRAY-UP A low-to-medium-volume, open mold method similar to hand lay-up in its suitability for making boats, tanks, tub/ shower units, and other simple medium-to-largesize shapes such as truck roofs, vent hoods, and commercial refrigeration display cases. Greater shape complexity is possible with spray-up than with hand lay-up. Process Description Fiberglass continuous strand roving is fed through a combination chopper and spray gun. This device simultaneously deposits chopped roving and catalyzed resin onto the mold. The laminate thus deposited is densified with rollers or squeegees to remove air

and thoroughly work the resin into the reinforcing strands. Additional layers of chopped roving and resin may be added as required for thickness. Cure is usually at room temperature or may be accelerated by moderate application of heat. As with hand lay-up, a superior surface finish may be achieved by first spraying gel coat onto the mold prior to spray-up of the substrate. Woven roving is occasionally added to the laminate for specific strength orientation. Also, core materials are easily incorporated. Resin Systems General-purpose, room-temperature curing polyesters, low heat-curing polyesters. Molds Simple, single-cavity, usually one-piece, either male or female, as with hand lay-up molds. Occasionally molds may be assembled in several pieces, then disassembled when removing the part. This technique is useful when part complexity is great. Major Advantages Simple, low-cost tooling, simple processing; portable equipment permits on-site fabrication; virtually no part size limitations. The process may be automated. VACUUM BAG MOLDING A flexible film (PVA or cellophane) is placed over the completed lay-up or sprayup, its joints sealed, and a vacuum drawn. Atmospheric pressure eliminates voids in the laminate, and forces excess resin and air from the mold. The addition of pressure further results in higher glass concentration, and provides better adhesion between layers of sandwich construction.

Pressure Bag Molding A tailored rubber sheet is placed against the finished lay-up or spray-up, and air pressure is applied between the rubber sheet and a pressure plate. (Steam may be applied to heat the resin to accelerate cure.) Pressure eliminates voids and drives excess resin and air out of the laminate, densifying it and improving the off-mold surface finish. This process is not compatible with male molds.

Autoclave Molding Either vacuum bag or pressure bag process can be further modified by the use of an autoclave, which provides additional heat and pressure, producing greater laminate densification and faster cure. This process is usually employed in the production of highperformance laminates using epoxy resin systems in aircraft and aerospace applications.

PRESSURE BAG MOLDING Suited primarily to the production of seamless FRP tanks for water softening, water handling and storage applications, filtration tanks, and fire extinguisher tanks. Process Description A fiberglass preform is made by spray-up, mat fabrication, or a combination of methods. An inflatable elastic pressure bag is positioned within the preform and the assembly placed into a cold closed mold. Resin is injected into the mold and the pressure bag is inflated to about 275 kPa (40 psi). Heat is applied and the part is cured within the mold. When cure is complete, the bag is deflated and pulled through an opening at one end of the molded part. The part is then removed from the mold. Molds Steel "clamshell" molds, hollow, with provisions for injection of resin. Comparatively inexpensive for metal closed molds. Resin Systems Polyesters, general-purpose and semi rigid, chemical-resistant, low-moistureabsorption types. Major Advantages Specialized process yields pressure vessels of one-piece construction at moderately high production rates. Large vessels are possible with the process. Mold cost is low to moderate. Process can use low-cost continuous strand roving, chopped in preform processing. Color can be molded in. Translucent containers which permit visual inspection of their contents can be produced by this process. FILAMENT WINDING A process resulting in a high degree of fiber orientation and high glass loading to provide extremely high tensile strengths in the manufacture of hollow, generally

cylindrical products such as chemical and fuel storage tanks and pipe, pressure vessels. and rocket motor cases. Process Description Continuous strand reinforcement is utilized to achieve maximum laminate strength. Reinforcement is fed through a resin bath and wound onto a suitable mandrel (pre-impregnated roving may also be used). Special winding machines lay down continuous strands in a predetermined pattern to provide maximum strength in the directions required. When sufficient layers have been applied. the wound mandrel is cured at room temperature or in an oven. The molding is then stripped from the mandrel. Equipment is available to perform filament winding on a continuous basis. Molds Mandrels of suitable size and shape, made of steel or aluminum, which form the inner surface of the hollow part. Some mandrels are designed to be collapsible, to facilitate part removal. Resin Systems Polyesters and epoxies

Major Advantages The process affords highest strength-to-weight ratio of any fiberglass-reinforced plastic manufacturing process, and provides highest degree of control over uniformity and fiber orientation. Filament-wound structures can be accurately machined. The process may be automated when high volume makes this economically feasible. The reinforcement used is low in cost. Integral vessel closures and fittings may be wound into the laminate.

CONTINUOUS PULTRUSION A continuous process for the manufacture of products having a constant cross section, such as rod stock, structural shapes beams, channels, pipe, tubing, and fishing rods. Process Description

Continuous strand fiberglass roving, mat or cloth is impregnated in a resin bath, and then drawn through a steel die which sets the shape of the stock and controls the resin/glass ratio. A portion of the die is heated to initiate the cure. With rod stock, cure is affected in an oven. A pulling device establishes production speed. Molds Hardened steel dies. Resin Systems General-purpose polyesters and epoxies. Major Advantages The process is a continuous operation and can be readily automated. It is adaptable to shapes with small cross-sectional areas, and uses low-cost reinforcement. Very high strengths are possible due to high fiber concentration and orientation parallel to the length of the stock being drawn. There is no practical limit to the length of stock produced by continuous pultrusion. CENTRIFUGAL CASTING A process for the production of cylindrical hollow shapes: water tanks, pipe, tubing, and containers. Process Description Chopped strand mat is positioned inside a hollow, cylindrical mold; or continuous strand roving is chopped and directed onto the inside walls of the mold, which is heated (82 to 93C; 180 to 200 F) and is rotating. Resin is applied to the inside of the rotating mandrel and centrifugal force distributes the resin thoroughly, impregnating the reinforcement. To accelerate cure, hot air is blown through the rotating mold. The mold is stopped and the finished part is removed. Resin Systems General-purpose and chemical-resistant polyesters. Molds Cylindrical metal tubing. Major Advantages The method can be automated to produce high volumes of pipe or tanks at low tooling cost. Good surfaces are provided inside and out. Low material waste and uniform, voidfree laminates are achieved. External threads may be molded in.

INJECTION MOLDING Highest-volume method of any of the fiberglass-reinforced plastic processes, using single- or multiple-cavity molds to produce very large volumes of complex parts at very high production rates, with a wide variety of mechanical, chemical, electrical, and thermal properties provided by the wide range of thermoplastic resins available. Process Description The molding compound - in pellet form, compound concentrate, or dry blend - is heated in the injection chamber of the molding machine. The material is then injected, either by plunger or reciprocating screw under high pressure and in hot, fluid form, into a relatively cold closed mold. After a short cooling cycle, usually 15 to 90 s, the compound is solidified to a degree sufficient to enable the part to be removed from the mold without distortion. A wide variety of small to medium size parts are routinely injection molded; household appliance parts, gears, pump housings, valve bodies, and large parts such as home laundry tubs, automobile instrument panels, fender liners, and other components requiring high dimensional stability and complexity of design. Resin systems All thermoplastics - notably nylon, acetal, vinyl, polycarbonate, polyethylene, polystyrene, polypropylene, polysulfone, modified polyphenylene oxide, fluorocarbons, ABS (acrylonitrile-butadiene-styrene), and SAN (styrene-acrylonitrile). (Some thermosets can also be injection molded.) Molds Single- or multiple-cavity, hardened tool steel molds. Major Advantages Highest volume and highest uniformity of part of any molding method. The process is usually highly automated. Great part precision and design flexibility are obtainable. Parts range from very small to quite large, with complex detail, and other design features not possible to mold in any other process. There is versatility with the many resin systems and compounds available, as well as pigmentation and additives for color and many special chemical or thermal properties. COMPRESSION MOLDING A high-volume, high-pressure method suitable for molding complex, highstrength fiberglass-reinforced plastic parts. Fairly large parts can be molded with excellent surface finish. Thermosetting resins are normally used.

Process Description Matched molds are mounted in a hydraulic or modified mechanical molding press. A weighed charge of sheet or bulk molding compound, or a "preform" or fiberglass mat with resin added at the press, is placed in the open mold. (In the case of preform or mat molding, the resin may be added either before or after the reinforcement is positioned in the mold, depending on part configuration.) The two halves of the mold are closed, and heat (105 to 160C; 225 to 320 OF) and pres sure (1.0 to 13.8 MPa; 150 to 2000 psi) are applied. Depending on thickness, size, and shape of the part, curing cycles range from less than a minute to about five minutes. The mold is opened and the finished part is removed. Typical parts: automobile front ends, appliance housings and structural components, furniture, electrical components, business machine housings and parts. Resin Systems Polyesters (combined with fiberglass reinforcement as bulk or sheet molding compound, preform, or mat), general-pur pose, flexible or semirigid, chemical resistant, flame retardant, high heat distortion; also phenolics, melamines, silicones, diallyl phthalate, some epoxies. Molds Single- or multiple-cavity hardened and chrome plated molds, usually cored for steam or hot oil heating; sometimes electric heat is used. Side cores, provisions for inserts, aJld other refinements are often employed. Mold materials include cast or forged steel, cast iron, and cast aluminum. Major Advantages Highest volume and highest part uniformity of any thermoset molding method. The process can be automated. Great part design flexibility, good mechanical and chemical properties obtainable. Inserts and attachments can be molded in. Superior color and finish are obtainable, contributing to lower part finishing cost. Subsequent trimming and machining operations are minimized. BULK MOLDING COMPOUNDS BMC or bulk molding compounds are formulated with chopped strand fiberglass, resin, thickener, pigment, filler and a catalyst as ingredients. Low-profile agents may also be used when surface finish is critical. The compound is taken in measured quantities by weight and placed into a heated cavity of a mold, where pressure and additional heat are applied. Curing time, temperature, and pressure are dependent on the type of mix and the shape of the product being molded. SHEET MOLDING COMPOUND SYSTEMS

PROCESS DESCRIPTION Sheet molding compounds for structural molding composites are made by depositing a chemically thickenable, low viscosity polyester resin uniformly on a continuous polyethylene carrier film. Continuous fiberglass rovings are then chopped to a predetermined length and randomly deposited on the resin. Others may be continuously deposited in the machine direction without chopping. Simultaneously, a second polyethylene carrier film is covered with a given amount of thickenable catalyzed polyester resin, and brought into contact with the first carrier film. The resultant resin-glass-resin sandwich is passed under kneading and/or compaction rolls to assist in wetting of the reinforcements to form a uniform sheet. The sheet is then wound onto a take-up roll. To ensure that the loss of styrene monomer is held at the lowest possible level, the rolls are wrapped and sealed with barrier film or foil. Reinforcement content is controlled by the speed of the carrier film passing under the deposition area, the quantities of roving being continuously deposited (if any) and chopped, and by the chopper speed. Rolls of compound are aged for a predetermined period of time to allow uniform viscosity rise before being prepared for molding. Since the compounds are nearly tackfree as they thicken, they can be readily cut into various shapes for mold charging and stripped of the polyethylene film by the press operator. Molds Following placement in the matched metal die and mold closing, isotropic sheet compounds flow uniformly throughout the integral contours of the mold to form the final part. Those containing continuous roving are limited to cross-directional flow.

Major Advantages Sheet molding compounds offer the molder many advantages. They can either be made by the molder himself or be purchased from a compounder, depending on volume. They are stable for 3 to 9 months if properly wrapped and stored at 16C (60 OF). Reuse of most edge and charge trim from the compound minimizes waste without adverse effect on the molded product. Parts have not only good physical properties, weatherability, and corrosion resistance with improved surfaces, but also a quite uniform glass/resin ratio throughout.

PREMIX COMPOUNDS In premix molding compounds, the fiberglass chopped strand along with resin, pigment, filler and catalyst are thoroughly mixed for use in bulk form. The premixed material is then formed, in some cases by extrusion, into accurately weighed premold charges, placed into the cavity of the mold, and molded under heat and pressure. Pressure used may be from 690 kPa to 10.3 MPa (100 to 1500 psi). Curing temperature may vary from 105 to 150C (225 to 300 OF). Curing time depends on the compound and the configuration of the molded part. Under most circumstances it lasts from 30 s to 5 min.

APPLICATIONS OF PMCs Industry Automotive Advantages High-volume production; Fine finishes, Reduced costs Agricultural Ruggedness; Corrosion resistance Applications Automobile body components; fender extenders; front ends; head lamp and tail lamp housings; hoods; spoilers, instrument panels; shift consoles; under-thehood components; truck hoods; fenders; cab and body components; insulated tanks; engine covers; housings; fender liners. Farm tractor hoods, grilles, instrument housings, seating, fenders; garden tractor and lawn mower bodies and housings; fertilizer and pesticide tanks and sprayers; feed troughs. resistance Room air conditioner cases, base pans, bulkheads; condenser and compressor fans; humidifier cases and blower wheels; dishwasher pump bodies; dryer ducts; home laundry tubs; water softener tanks, controls, piping; fan housings; gears; vacuum cleaner housings; iron handles; soap dispensers; microwave oven cook trays; television swivel stands; sump pump bases. Aircraft interior components for passengers and cargo; wing tips; antenna components; radomes; wing fuel tanks; ducting; rocket motor cases; nozzles; nose cones; pressure vessels; instrument housings; launch tubes. Machine covers and housings; access panels; keyboard caps; keys; printer heads; gears, cams, and levers; frames; mounting panels; printed circuit boards; fans and blowers. Chemical and fuel tanks, pipes, and ducting; storage tanks and hoppers; process pump and valve bodies, casings, impellers; pressure vessels; filters; fumecollection hoods and duct systems; scrubbing towers; electroplating racks and handling equipment; photographic processing equipment. Structural shapes; paneling; siding; sky lighting; curtain wall components; glazing panels; patio covers; concrete pouring forms. Electrical pole line hardware, crossarms, strain insulators, standoffs, brackets; shatterproof street lighting globes; switch control rods; hot sticks; electronic components; housings and backboards; utility line maintenance equipment.

Appliances

Ability to produce complex molded parts without fasteners or welds

Aviation/ Aerospace

High strength with light weight

Business machines

Chemical processing

Excellent surface finish and dimensional stability at elevated temperatures; Corrosion resistance

Construction

Electrical/ Electronics

Ruggedness, Moderate cost, Good appearance High dielectric strength with low moisture absorption

House

Beauty; Low maintenance; Low cost Ease of repair; low maintenance; high performance

Marine

Material Handling

High strength with light weight

Recreational

Low maintenance; Good appearance

Transportation

Toughness; Lightness

Architectural components; appliance and equipment components; furniture-chairs, tables, lawn furnishings; sinks; bathroom tub/ shower units; skylights. Pleasure, commercial, and military boat hulls and superstructures; barge covers; lighters; fuel tanks; water tanks; masts and spars; bulkheads; duct work; ventilation cowls; marker buoys; floating docks; outboard engine shrouds. Tote trays and bins; food-processing and delivery trays, boxes, bins; tanks and pipes; conveyor-system components; pallets and skids; cargo-handling equipment. Motor homes; travel trailers; truck campers; camping trailers; pickup covers; water and snow skis; surfboards; golf clubs; hockey sticks; lacrosse sticks; archery bows; fishing rods; vaulting poles; recreational water craft, canoes; snowmobile and allterrain vehicle bodies; golf carts; protective helmets; swimming pools; diving boards; playground equipment. Railway passenger and freight car components; transport seating; freight car roofs; hopper car covers; refrigerator car liners; air cargo "igloos"; motor truck and bus components; rapid transit car ends; third-rail covers; barges; truck trailer panels; refrigerated truck bodies.

Applications of Polymer Matrix Composites by Manufacturing Method Manufacturing method Filament winding Press molding Applications Pressure bottles, silos, tubing, pipe, missile shells, nozzles. Car bodies, housings, chemical equipment, electrical equipment, appliances, covers, lamp shades, sinks, tanks. Rods, tubes, shapes, structural, building components, electrical appliances. Boats, silos, car bodies, scooters, motorcycles, furniture, trucks, homes, chemical tanks, swimming pools, bathtubs, plumbing fixtures. Aircraft parts, propeller blades, high strength parts, radomes.

Pultrusion Spray molding, Contact lay-up Autoclave molding

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