By combining specific resins and reinforcements and there are a lot of them
you can customize the formulation to meet specific strength requirements of any
application. For example, you can alter the ratio of the resin and reinforcement
or orient the fibers in one direction or various directions.
Specific Strength
Tensile Strength
Tensile strength refers to the amount of stress a material can handle before it
breaks, cracks, becomes deformed or otherwise fails. One measure of tensile
strength is flexural strength a material or structures ability to withstand
bending. Tensile and flexural strength are important measurements for engineers
and designers. Imagine building a bridge deck or a ceiling without knowing how
much stress it could take before collapsing?
Shear Strength
Shear strength describes how well a material can resist strain when layers shift
or slide. Its important to know the maximum amount of shear stress (or force
per unit area) a material can handle prior to failure. This lets engineers and
designers know the amount of weight or load a structure can support and
what may happen to the structure when forces are applied in different directions.
Shear strength in composites varies based on the formulation and design.
Composites can be designed so shear stresses are oriented within a plane,
transverse to the plane or throughout the layers (interlaminar). There are several
ways to control shear properties, including fiber orientation, the sequencing of
layers, the type and volume of fibers used, the type and density of core materials
and more.
Compressive Strength
Light weight
Easy Installations
One of the top advantages of using lightweight composites is that they are
simple to handle, transport and install. This saves time on projects. Wolf Trap
National Park in Virginia installed a pedestrian bridge with FRP decks in 2012.
The bridge was 80 percent lighter than a concrete one, making it faster to lift,
move and place by crane. The deck was installed in three days, while a concrete
one wouldve taken at least four weeks. Lightweight composites also simplify
installations in remote locations, such as utility poles in marshlands or pipelines
on mountains.
Reduced Costs
Lighter parts and products often save money. And saving on weight and cost is
music to the ears of many end users. NASA and Boeing recently tested an all-
composite cryogenic tank used to carry fuel on deep space missions. The tank,
one of the largest and lightest ever manufactured, is the latest step toward the
planned 8.4-meter tank that could reduce the weight of rocket tanks by 30
percent and cut launch costs by at least 25 percent.
Adherence to Standards
Composites are often the answer when applications need to meet specific
standards and regulations. The most notable example relates to fuel efficiency.
Within the automotive industry, meeting Corporate Average Fuel Efficiency
(CAFE) standards of 36.6 mpg by 2017 and 54.5 mpg by 2025 provides impetus
for using lightweight materials. Major OEMs have optimistic plans often
involving composites to drastically reduce the gross weight of vehicles. In 2013,
GM introduced the Chevrolet Silverado Cheyenne concept vehicle featuring some
carbon fiber-reinforced parts. Its approximately 200 pounds lighter than the base
curb weight of the 5.3L Silverado. Volkswagen created the Transporter, a utility
concept truck weighing just 3.5 tons. It saves on diesel consumption and carbon
dioxide emissions by providing 40 percent more payload and up to 30 percent
savings in shipments.
Resistance
Composites do not rust or corrode. There are many examples of glass fiber
reinforced polymer ductwork being in service in chemical manufacturing plants
for more than 25 years, operating in harsh chemical environments 24 hours a
day, seven days a week. Composites offer corrosion-resistant solutions for many
industries, including air pollution control, chemical processing, desalination, food
and beverage, mineral processing and mining, oil and gas, pulp and paper, solid
waste landfill and water and wastewater treatment.
In 1961, the Amoco Division of Standard Oil introduced the first underground
gasoline storage tank. Between 1961 and 1965, Shell Oil and Owens Corning
researched corrosion-resistant solutions, ultimately producing the first
commercial line of large composite underground storage tanks.
One of the primary functions of resins in composites is to protect the fibers they
surround. There are dozens of resins designed to provide corrosion resistance.
Each unique formulation offers protection against specific conditions, such as
caustic solutions, acidic environments, alkaline environments, oxidizing
chemicals and high temperatures.
The first corrosion resins employed bisphenol fumurate and chlorendic anhydride
resin chemistries. Subsequently, isophthalic resins were developed and became
the mainstay of corrosion-resistant resins. Isophthalic resins along with epoxy
vinyl ester resins are commonly used today.
While the same resin matrix will typically be used throughout the composite
structure, reinforcements may be used in three specific areas of the laminate. A
fiberglass or synthetic veil is used at the inner surface of the laminate. The inner
surface is the interface of the composite and corrosive material. The veil serves
to provide a resin-rich (90% resin) surface for the composite while preventing
micro-cracks in the resin which would otherwise occur if a resin-only surface (or
gel coat) was attempted. The next layer is the chopped fiberglass layer which
provides a more robust backup for the veil and is also resin-rich (70% resin). This
layer is usually considerably thicker than the veil layer and when combined with
the veil layer forms a 100 to 200 mil thick corrosion barrier. The last layer, and
by far the thickest layer is the structural portion of the laminate. Different forms
of fiberglass reinforcements can be used in this layer to provide a high glass
content (35% resin, 65% reinforcement) structural layer: direct draw single-end
rovings, fabrics, or choppable reinforcements.
There is a vast choice of materials used for the veil layer since this is the first line
of defense against a corrosive assault. C-glass, E-CR glass, several types of
synthetics thermoplastic non-wovens and carbon veil are the main material
choices for veils. Each has a specific environment where they excel. E-glass is
almost never used due to its poor corrosion performance. The material choices
for the chopped fiberglass layer and the structural layer narrow considerably to
E-glass and E-CR glass.
While there are more than a dozen standards associated with construction design
related to composite corrosion applications, the primary one is ASTM C582. Its a
standard specification for contact-molded reinforced thermosetting plastic (RTP)
laminates for corrosion-resistant equipment. It covers composition, thickness,
fabrication procedures and physical property requirements for corrosion-resistant
tanks, piping and equipment manufactured by contact molding also known as
open molding.
ecause composites are a blend of reinforcing fibers, resins and additives, they
can be manufactured to meet an array of requirements. Designers are free to
create exciting new products and, in many cases, are only limited by their
imagination. Applications ranging from sports cars to wind blades take
advantage of the inherent design flexibility of composites to produce complex
shapes, add specific properties and enhance aesthetics.
Design flexibility
Innovative Geometries
One of the biggest benefits of composites is the ability to mold them into
complicated shapes more easily that most other materials. Intricate shapes and
contours are possible without the need for high-pressure tools because
composites are formed when the resin cures or solidifies during production.
So composite parts can easily take on many shapes, whether theyre created in
low volumes manually or manufactured using high-volume, automated
processes.
Designers like working with composites because parts can be tailor-made to have
strength and stiffness in specific directions and areas. For instance, a composite
part can be made to resist bending in one direction. The strategic placement of
materials and orientation of fibers allows companies to design parts and products
to meet unique property requirements.
Being able to address high stress and strain areas is critical in several markets,
such as sports and recreation, where both high-end and everyday applications
count on composites. At the elite level of competition, racing yachts in the
biannual Americas Cup rely on exacting design of composite parts to carry
structural loads throughout the yachts hulls and cross beams. By aligning fibers
in various patterns laterally across skis, you can improve the torsional rigidity
the skis ability to resist twisting forces.
Surface Appearance
But aesthetics arent reserved solely for luxury markets. Composite surfaces can
be molded to simulate any finish or texture, from smooth to coarse. Consumers
opt for composite countertops because they can be formed into any shape and
customized into any color. Handles and knobs on household appliances look
stylish and feel good to the touch. With composites, designers have endless
options to create beautiful products.
Durability
Resistant to Fatigue
Weather Warriors
Reduced Maintenance
Resin
There are two major groups of resins that make up what we call
polymer materialsthermosets and thermoplastics. These
resins are made of polymers (large molecules made up of long
chains of smaller molecules or monomers).
Thermosetting
Thermoplastics
Epoxy
Fibers
Reinforcement Forms
Woven, Stitched, Braided & 3-D Fabrics: There are many types
of fabrics that can be used to reinforce resins in a composite.
Multidirectional reinforcements are produced by weaving,
knitting, stitching or braiding continuous fibers into a fabric
from twisted and plied yarn. Fabrics can be manufactured
utilizing almost any reinforcing fiber. The most common fabrics
are constructed with fiberglass, carbon or aramid. Fabrics offer
oriented strengths and high reinforcement loadings often found
in high performance applications. Fabrics allow for the precise
placement of the reinforcement. This cannot be done with
milled fibers or chopped strands and is only possible with
continuous strands using relatively expensive fiber placement
equipment. Due to the continuous nature of the fibers in most
fabrics, the strength to weight ratio is much higher than that for
the cut or chopped fiber versions. Stitched fabrics allow for
customized fiber orientations within the fabric structure. This
can be of great advantage when designing for shear or
torsional stability.
Milled: Milled fibers are chopped fibers having very short fiber
lengths (usually less than 1/8). These products are often used
in thermoset putties, castings, or syntactic foams to prevent
cracking of the cured composition due to resin shrinkage.
Core
Linear PVC Foam: Linear PVC foam core is produced mainly for
the marine industry. Its unique mechanical properties are a
result of a non-cross-linked molecular structure, which allows
significant deflection before failure. In comparison to the
crosslinked (non-linear) PVC, this PVC will exhibit less favorable
static properties and better impact absorption capability.
Surface Finishes
Hand Lay-Up
Hand lay-up is an open molding method suitable for making a
wide variety of composites products from very small to very
large. Production volume per mold is low; however, it is feasible
to produce substantial production quantities using multiple
molds. Hand lay-up is the simplest composites molding method,
offering low cost tooling, simple processing, and a wide range
of part sizes. Design changes are readily made. There is a
minimum investment in equipment. With skilled operators,
good production rates and consistent quality are obtainable.
Process:
Gel coat is first applied to the mold using a spray gun for a high
quality surface. When the gel coat has cured sufficiently, roll
stock fiberglass reinforcement is manually placed on the mold.
The laminating resin is applied by pouring, brushing, spraying,
or using a paint roller. FRP rollers, paint rollers, or squeegees
are used to consolidate the laminate, thoroughly wetting the
reinforcement and removing entrapped air. Subsequent layers
of fiberglass reinforcement are added to build laminate
thickness. Low density core materials such as end-grain balsa,
foam, and honeycomb, are commonly used to stiffen the
laminate. This is known as sandwich construction.
Molds:
Spray-Up
In the spray-up process, the operator controls thickness and
consistency, therefore the process is more operator dependent
than hand lay-up. Although production volume per mold is low,
it is feasible to produce substantial production quantities using
multiple molds. This process uses simple, low cost tooling and
simple processing. Portable equipment permits on-site
fabrication with virtually no part size limitations. The process
may be automated.
Process:
As with hand lay-up, gel coat is first applied to the mold and
allowed to cure. Continuous strand glass roving and initiated
resin are then fed through a chopper gun, which deposits the
resin-saturated chop on the mold. The laminate is then rolled
to thoroughly saturate the glass strands and compact the chop.
Additional layers of chop laminate are added as required for
thickness. Roll stock reinforcements, such as woven roving or
knitted fabrics, can be used in conjunction with the chopped
laminates. Core materials of the same variety as used in hand
lay-up are easily incorporated.
Molds:
These are the same molds as hand lay-up: simple, single cavity
molds of fiberglass composites construction. Molds can range
from small to very large and are low cost in the spectrum of
composites molds.
Filament Winding
Process:
Molds:
Closed Molding
Vacuum Bag Molding
Process:
Molds:
Vacuum Infusion
Processing
Vacuum infusion can produce laminates with a uniform degree
of consolidation, producing high strength, lightweight
structures. This process uses the same low-cost tooling as open
molding and requires minimal equipment. Vacuum infusion
offers substantial emissions reduction compared to either open
molding or wet lay-up vacuum bagging.
Process:
The mold may be gel coated in the traditional fashion. After the
gel coat cures, the dry reinforcement is positioned in the mold.
This includes all the plies of the laminate and core material if
required. A perforated release film is placed over the dry
reinforcement. Next a flow media consisting of a coarse mesh
or a crinkle ply is positioned, and perforated tubing is
positioned as a manifold to distribute resin across the laminate.
The vacuum bag is then positioned and sealed at the mold
perimeter. A tube is connected between the vacuum bag and
the resin container. A vacuum is applied to consolidate the
laminate and the resin is pulled into the mold.
Molds:
Process:
Molds:
RTM can utilize either hard or soft tooling depending upon the
expected duration of the run. Soft tooling would be either
polyester or epoxy molds, while hard tooling may consist of
cast machined aluminum, electroformed nickel shell, or
machined steel molds. RTM can take advantage of the broadest
range of tooling of any composites process. Tooling can range
from very low-cost to high-cost, life-long molds.
Compression Molding
There are several types of compression molding that are
defined by the type of material molded: sheet molding
compound (SMC), bulk molding compound (BMC), thick molding
compound (TMC), and wet lay-up compression molding.
Compression molding tooling consists of heated metal molds
mounted in large hydraulic presses. The process can be
automated. Compression molding enables part design flexibility
and features such as inserts, ribs, bosses and attachments.
Good surface finishes are obtainable, contributing to lower part
finishing cost. Subsequent trimming and machining operations
are minimized in compression molding and labor costs are low.
Process:
Molds:
Pultrusion
Pultrusion produces profiles with extremely high fiber loading;
thus, pultruded products have high structural properties. The
process can be readily automated and is adaptable to both
simple and complex cross-sectional shapes. Very high strengths
are possible and labor costs are low.
Pultrusion Diagram
Process:
Molds:
Reinforced Reaction
Injection Molding
(RRIM)
RRIM composites have a number of processing advantages
including very fast cycle time, low labor, low mold clamping
pressure and low scrap rate. RRIM uses reinforcements to
improve the properties of the resin. With the use of
reinforcements, polymerization shrinkage is reduced, thermal
expansion is reduced, droop and sag of the composite at
elevated temperatures is minimized and other key properties
such as stiffness, tensile strength and tensile elongation are
generally improved. Milled fibers or flakes can be added directly
to the resin before reacting in the mixing head.
Applications:
Centrifugal Casting
With centrifugal casting, the outside surface of the part, which
is cured against the inside surface of the mold, represents the
finished surface. The interior surface of centrifugally cast
parts can be given an additional coating of neat or pure resin
to improve surface appearance and provide additional chemical
resistance in the part. Large diameter composite pipe and tanks
are commercially produced by centrifugal casting.
FIBER
MATRIX
What Are Composites - Matrix
Ancient Times
The 1930s heralded a new era for resins and ultimately the
composites industry as a whole. Unsaturated polyester resins
were patented in 1936 by Carleton Ellis. Because of their curing
(or hardening) properties, they became the primary choice for
resins in composites manufacturing. By the late 1930s, other
high-performance resin systems had become available,
including epoxy resins.
A New Era
A Growing Industry
Composites continued to take off after the war and grew rapidly
through the 1950s: Boats, trucks, sports cars, storage tanks,
pipes, ducts and many other products were built using
composites. In 1953, the 1st production Chevrolet Corvette with
fiberglass body panels rolled off the assembly line. Also in the
early 1950s, manufacturing methods such as pultrusion,
vacuum bag molding, and large-scale filament winding were
developed. Filament winding became the basis for the large-
scale rocket motors that propelled exploration of space in the
1960s and beyond.
Widespread Use
During the late 1970s and early 1980s, composites were first
used in a number infrastructure applications in Europe and
Asia, including the worlds first highway bridge using
composites reinforcing tendons and the first all-composites
bridge deck. The 1990s saw the first all-composites pedestrian
bridge installed in Aberfeldy, Scotland; the first FRP reinforced
concrete bridge deck built in McKinleyville, West Virginia; and
the first all-composites vehicular bridge deck in Russell, Kansas.
Numerous FRP composites pedestrian bridges have been
installed in U.S. state and national parks in remote locations not
accessible by heavy construction equipment, or for spanning
over roadways and railways.
3D Printer Composites Additive Manufacturing Illustration
Modern Day
Looking Ahead
Industry Overview
The global appetite for composites is strong and continues to
flourish as composites fuel the growth of new applications in a
number of markets.
Consumer Composites
Advanced Composites