Compounding
Alloying
Blending
Filling / Adding
Difference?
Compounding
Quality .Quantity
More Cost.Less
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Additives and Fillers: To change and improve 1.Physical 2.Mechanical 3.Processing properties
Additives and Fillers: 1.Colorants 2.Plasticizers 3.Flame retardants 4.Antistatic agents 5.Heat Stabilizers 6.Anti-oxodants 7.UV Light Absorbers 8.Blowing Agents 9.Coupling Agents 10.Fillers
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1.Additives:
COLORANTS
1.Additives: COLORANTS
Provide colour-fastness when exposed to light, temperature, humidity, chemicals
Without reducing other properties like Flow during processing, Resistance to chalking & Impact strength
2. Additives:
PLASTICIZERS
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2.Additives: PLASTICIZERS
Enhance flexibility, resiliency, & melt flow of plastics Act like internal lubricants by reducing VanderWaals forces between polymer chains & by preventing them from intermeshing
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3.Additives:
FLAME RETARDANTS
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Insulate plastic, create endothermic cooling reaction, coat plastic excluding oxygen
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5. Additives: HEAT STABILIZERS Prevent degradation of resins during processing when melts subjected to high temperatures
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6. Additives: ANTIOXIDANTS
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7. Additives: UV LIGHT ABSORBERS stabilize colour & lengthen life of product because virtually every plastic degrades in sun-light through discoloration & loss of
physical properties Years of outdoor Exposure
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10. Additives:
FILLERS Inorganic (e.g: Glass fibres )
Organic (e.g:wood)
Mineral (e.g: Calcium Carbonate, Silica & Clay) Used with thermosetting resins Like Phenolics, Ureas and Melamines
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Because Properties of extended plastic often decrease, use limited to less critical applications
One of the most widely used filler is wood flour (Which country?) Maple Flour
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Polymer Composites
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Objective of Capsule: What are composites Why do we need composites Typical Applications
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+ 4 + 5?
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1.Composite?
2.Macintosh?
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Macintosh
Why do we make composites? To make a material that has the properties of both its components.
We combine the water-resistance of Polyisoprene and the comfort of Cotton.
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Composite
Fibre Matrix
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Composite
Fiber
Glass / Kevlar / Carbon / PE Matrix
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Composites
Particle Based
Magneto Cover
Fibre Reinforced
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Composites
Fibre Reinforced
Particulates:
Spheres Rods Flakes Aspect Ratio ~1
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Composite Properties affected by: Size, Shape Amount & Distribution Modulus
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Fiber Composites
Particle Board
MDF Board
Plywood
Isotropy
(Random Particulate)
Properties Orthotropy
(Continuous Fiber)
Anisotropy
(Aligned Short fiber)
Fiber embedded in the matrix in order to make the matrix stronger Advantages of Fiber Reinforcement in cars
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Fiber-reinforced composite
Fiberglas
Pour mix of Styrene & Polyester over mass of glass fibers Styrene & double bonds in polyester react by Polymerization to form cross-linked resin Glass fibers trapped inside, acting as reinforcement
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What does the matrix do for fiber? Why not just use fibers by themselves? 1.Function of Matrix Matrix holds the fibers together Loose bundle of fibers wouldn't be of much use
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2. Function of Matrix
Though fibers are strong, they can be brittle Matrix can absorb energy by deforming under stress.(i.e) matrix adds toughness to composite
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3.Function of Matrix While fibers have good tensile strength, they usually have low compressive strength That is, they buckle when you squash them Matrix gives compressive strength to composite
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Properties of Glass Fibers Glass Sp. Tensile Tm Applications 0C Strength Grad Gravity MPa e A ?
E ECR ? ?
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Properties of Glass Fibers Glass Sp. Tensile Tm Applications 0C Strength Grad Gravity MPa e A 2.50
E ECR 2.58 2.62
2.48
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Properties of Glass Fibers Glass Sp. Tensile Tm Applications 0C Strength Grad Gravity MPa e A 2.50 3040
E ECR 2.58 2.62 3450 3625
2.48
4590
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Properties of Glass Fibers Glass Sp. Tensile Tm Applications 0C Strength Grad Gravity MPa e A 2.50 3040 996
E ECR 2.58 2.62 3450 3625 1065 1204
2.48
4590
1454
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Properties of Glass Fibers Glass Sp. Tensile Tm Applications 0C Strength Grad Gravity MPa e A 2.50 3040 996 Good Chem. Resistance E 2.58 3450 1065 Electrical Grade (PCB) ECR 2.62 3625 1204 Elec.+ Chem.
S 2.48 4590 1454 Strength + Thermal
Stability (Air-craft)
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C Grade Coupling Agent Imparts lubricity Resin Compatibility Dimensional Stability Adhesion with Matrix Protection from handling damage
Wrt UTS
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Kevlar: Tends to be tougher Can absorb more energy without breaking Can stretch a little to keep from breaking, more so than carbon fiber can
Carbon-Kevlar
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20%
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Matrix needs only to wet & form a continuous phase around the reinforcement
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Properties of Composites
Matrix Reinforcement Properties Improved
Mechanical Strength Elevated Temp. Strength Chemical Resistance Anti-static Electrical Resistance EMF Shielding Flexibility Wear Resistance Energy Absorption Thermal Stability 59
Thermosets Carbon Thermoplasts Glass Organic Fiber Glass Bead Ceramic Particle Metal wire
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Applications of Composites
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Golf Club
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Should be As light as possible As strong as possible Can bend but should not break
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LCA Tejas
Empty:5,500 kg
Loaded:8,500 kg
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Conclusion:
Generally Composites are characterized by: 1. Density 2. Specific strength 3. Specific Stiffness 4. High-temperature performance limits 5. Wear resistance
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Cost
?
Weight
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Cost
Aero Space
Automotive
Weight
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Think Composites
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Thank You
pgschool@nttf.co.in
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