Assignment : Composite Materials - Terminology

Define the following terms and specify their interaction in typical composite structure:
a.    A-stage
It is an early stage in the reaction of a thermosetting resin in which the materials is
still soluble and fusible. The components of the resin (base material and hardener)
have been mixed but the chemical reaction has not started. The resin is in the A
stage during a wet layup procedure
b.    B-stage
An intermediate stage in the reaction of a thermosetting resin in which the material
melts when heated and dissolves in certain solvents. Materials are usually precured
to this stage to facilitate handling and processing prior to final cure. The components
of the resin have been mixed and the chemical reaction has started. The material has
thickened and is tacky. The resins of prepreg materials are in the B stage. To prevent
further curing the resin is placed in a freezer at 0 °F. In the frozen state, the resin of
the prepreg material stays in the B stage. The curing starts when the material is
removed from the freezer and warmed again.
c.    C-stage
The final stage of the curing of a thermosetting resin in which the material has
become infusible and insoluble in common solvents. The resin is fully cured. Some
resins cure at room temperature and others need an elevated temperature cure cycle
to fully cure.
d.    Accelerator
An additive to polyester resin that reacts with a catalyst to speed up polymerization.
This additive is required in room temperature cured resins.
e.    Autoclave
A closed vessel for producing an environment of fluid pressure, with or without heat,
to enclosed object while undergoing a chemical reaction or other operation.
f.     Balanced laminate
A composite laminate in which all the laminate layer are at the angles other than 0
and 90 occur only in positive pairs and are symmetrical around the centreline.
g.    Bi-directional fabric
Reinforcing fibers that are arranged in two directions, usually at right angles to each
other.
h.    Bleeder
Is a non structure layer of material used in the manufacture of composite parts to
allow the escape of excess gas and resin during cure. The bleeder cloth is removed
after the curing process is complete and is not part of the final composition.
i.     Blocking
Its source data from very large spamtraps /mail infrastructures
j.     Bridging
The condition which fibers do not move into or conform to radii and corners during
molding, resulting in voids and dimensional control problems.
k.    Catalyst
It is a substance that changes the rate of chemical reaction without it undergoing
permanent change in composition or becoming a part of the molecular structure of
the product. The substance will speed up the curing of a compound remarkably
when added in small quantity s compared to the amounts of primary reactants.
l.     Caul plate
It is a smooth metal, plastic, or rubber plates free of surface defects. A caul plate
must be the appropriate size and shape for the composite lay-up with which it will be
used. It is used in immediate contact with the lay-up during the curing process to
transmit normal pressure and provide a smooth surface on the finished part
m.   Core separation
A low density material used between two FRP skins. Examples of core materials are
end-grain balsa wood, urethane foam, PVC foam and various honeycomb materials.
n.    Core splicing
The joining of segments of a core by bonding, or by overlapping each segment and
then diving them together.
o.    Crazing
Cracking of gel coat or resin due to stress.
p.    Cure
Is to change the properties of a thermosetting resin which irreversible by chemical
reaction. Cure may be accomplished by addition of curing agents, with or without
catalyst and heat.
q.    Cure stress
Is a residual internal stress produced during the curing cycle of composite structure.
Normally, these stresses originate when different components of wet lay-up have
different thermal coefficients of expansion.
r.     Exothermic reaction
Internally developed heat accompanying a chemical reaction, such as might be
created when curing a thermosetting resin.
s.    Fabric - plain, satin and twill weave
Plain Weave
It is a woven with an ‘over one and under one’ configuration and is used for most flat
surfaces
Stain Weave
Stain Weave has a glossy surface and a dull back. The satin weave is characterized
by for or more fill or weft yarns floating over a warp yarn or vice versa, four warp
yarns floating over a single weft yarn. Floats are missed interfacings, where the warp
yarn lies on top of the weft in a warp-faced satin and where the weft yarn lies on top
of the warp yarns in weft-faced satins.
 Twill weave
Twill weave has a weave with an ‘over one and under two’ configuration, which gives
drapeability and is used where curve component shapes are required.
t.     Fibre – content
It is the amount of fibre present in a composite. This is usually expressed as a
percentage volume fraction or weight fraction of the composite.
u.    Fibre - direction
It is the alignment of the longitudinal axis of the fibre with respect to a stated
reference axis.
v.    Fill (weft, woof)
Yarn oriented at right angles to the warp in a woven fabric.

w.    Finish
It is the material applied to fibers, after sizing is removed in order to improve the
matrix-to -fiber coupling.
x.    Gel condition
A quick setting resin applied to the surface of a mold and gelled before lay-up.
y.    Glass (E and S)
E-Glass- knows as "Electrical" glass, the borosilicate glass most often used for the
glass fibers in conventional reinforced plastics.
S-Glass- is a Structural glass which might be a magnesia/alumina/silicate glass
reinforcement designed to provide very high tensile strength.
z.    Carbon FRP
 Carbon fiber reinforced plastic (or Carbon fiber reinforced polymer) is a very strong,
light weight composite  in which Carbon  constitutes the reinforcing fibers.   The
matrix resin system will usually be epoxy, polyester, vinyl ester or nylon.
aa.  Glass FRP
 Glass Fiber Reinforced Plastic uses fiber glass material  with an appropriate matrix
resin system.
bb.  Inhibitor
An additive to polyester resin or styrene used to slow the chemical reaction which
leads to curing.
cc.   Kevlar (Aramid)
Aramid fibers are light weight, strong, and tough. Two types of Aramid fiber are used
in the aviation industry, that is Kevlar 49 and Kevlar 29. Kevlar 49 has high stiffness
while Kelvar 29 has low stiffness
dd.  Kevlar FRP
Kevlar in cloth form and it is soft, yellow, organic fibre that is extremely light, strong
and tough. Its great impact resistacne makes it useful in areas, which are liable to be
struck by debris, as experienced in areas around engine reverse thrust buckets.
 Kelvar is used to manufacture bullet proof jacket, and also as a reinforcement in
aircraft fuel tanks.

ee.  Lamination sequence (Stacking or nesting)

Primarily means a composite material system made with layers of fiber reinforcement
in a resin. Sometimes used as a general reference for composites, regardless of how
made. Example of usage is laminate consumption by market, compression-molded
laminate.
ff.    Lay up
The reinforcing materials that placed in position in the mold. The process of placing
the reinforcing material in position to the mold. A description of the component
materials, geometry and so forth, of a lamination.
gg.  Matrix
It is a materials in which the fiber of a composite is imbedded. That composite can be
plastic, metal, ceramic or glass.
hh.  Micro cracking
Cracks formend in composites when thermal or mechanical stresses locally exceed
the strength of the matrix. Since most microcracks do not penetrate the reinforcing
fibers, microcracks in a cross-piled tape laminate or in a laminate made from cloth
prepreg are usually limited to the thickness of a single ply.
ii.     Mold release agent
A lubricant, liquid, or powder (often silicone oils and waxes), used to prevent sticking
of molded articles in the cavity.
jj.     Peel ply
Layer of material applied to a layup surface that is removed from the cured laminate
prior to bonding operations and leaves a clean resin-rich surface ready for bonding.
kk.   Ply orientation
The basic engineering properties of composite structures are derived form the
orientation of the fibers in cach layer(ply) and the ply position through-the-thickness.
The ply orientation will determine the longitudinal tension, transverse tension, bearing
and shear strengths of the composite laminated. The ply stacking sequence will
impact bearing strength and the load by- pass/bearing interaction between rows of
fasteners.
ll.     Porosity
Entrapped gas bubbles or voids in a gel coat film.
mm. Post-cure
To cure by application of heat after the chemical exothermic reaction has subsided.
nn.  Pot life
The length of time a catalyzed thermosetting resin system retains a viscosity low
enough for it to be suitable for processing
oo.  Prepeg
 Prepreg material consists of a combination of a matrix and fiber reinforcement. It is
available in one direction of reinforcement (unidirectional form) and several directions
of reinforcement (fibre form).
pp.  Reinforced plastic
The amount of resin in a laminate expressed as either a percentage of total weight or
total volume.
qq.  Resin content
The amount of resin in a laminate expressed as either a percentage of total weight or
total volume.
rr.    Resin richness
Localized area filled with resin but lacking reinforcement fiber.
ss.  Resin starvation
Localized area lacking sufficient resin for wet-out of the fibers.
tt.    Tracer
A fiber, tow, or yarn added to a prepreg for verifying fiber alignment and, in the case
of woven materials, for distinguishing warp fibers from fill fibers.
uu.  Unidirectional fabric
Srength lying mainly in one direction. A glass reinforcement in which the fiber is
oriented in one direction.
vv.   Void
Air or gas that has been trapped and cured into a laminate. Porosity is an
aggregation of microvoids. Voids are essentially incapable of transmitting structural
stresses or nonradiative energy fields.
ww. Warp
The yarn running lengthwise in a woven fabric. A group of yarns in long lengths and
approximately parallel. Also, a change in dimension of a cured laminate from its
original molded shape.
xx.   Warp clock
A composite fabrication and engineering symbol use as reference for aligning the
wrap yarns or tows in the desired direction.