NAME :-------------- PRAJESH KUMAR JHA SEMESTER:-------- 1st ( 2010-11) COURSE:------------ M.E.

(Advanced Material Technology) SUBJECT :---------- COMPOSITE MATERIALS

PREPARED FOR SUBMISSION AS AN ASSIGNMENT TO

DR. H.K. SHIVANAND

ASST. PROFESSOR DEPTT. OF MECH. ENGG. U.V.C.E., BANGALORE

According to the classification on the basis of type of matrix, there are three types of composite materials: -------------

A.) B.) C.)

METAL MATRIX COMPOSITES POLYMER MATRIX COMPOSITES CERAMICS MATRIX COMPOSITES

COMPOSITE MATERIALS

METAL MATRIX COMPOSITES

POLYMER MATRIX COMPOSITES

CERAMIC MATRIX COMPOSITES

Fibreglasses Glass Fiber Reinforced Polymers

Carbon Fiber Reinforced Polymer Composites Kevlar (aramid) fiber reinforced polymers

Polymer Matrix Composites (introduction)

Polymer Matrix Composite (PMC) is the material consisting of a polymer (resin) matrix
combined with a fibrous reinforcing dispersed phase. Polymer Matrix Composites are very popular due to their low cost and simple fabrication methods. Use of non-reinforced polymers as structure materials is limited by low level of their mechanical properties: tensile strength of one of the strongest polymers - epoxy resin is 20000 psi (140 MPa). In addition to relatively low strength, polymer materials possess low impact resistance.

ADVANTAGES OF PMCs
Reinforcement of polymers by strong fibrous network permits fabrication of Polymer Matrix Composites (PMC) characterized by the following properties:

High tensile strength; High stiffness; High Fracture Toughness; Good abrasion resistance; Good puncture resistance; Good corrosion resistance; Low cost.

DISADVANTAGES OF PMCs
The main disadvantages of Polymer Matrix Composites (PMC) are:

Low thermal resistance; High coefficient of thermal expansion.

Two types of polymers are used as matrix materials for fabrication composites:
1.) Thermo sets (epoxies, phenolics) and

2.) Thermoplastics (Low Density Polyethylene (LDPE), High Density Polyethylene

(HDPE), polypropylene, nylon, acrylics).

According to the reinforcement material the following groups of Polymer Matrix Composites (PMC) are used:
1.) Fibreglasses Glass Fiber Reinforced Polymers;

2.) Carbon Fiber Reinforced Polymer Composites;

3.) Kevlar (aramid) fiber reinforced polymers.

Reinforcing fibers may be arranged in different forms:

Unidirectional fibers; Rovings; Veil mat: thin pile of randomly orientated and looped continuous fibers; Chopped strands: thin pile of randomly orientated and looped short (3-4 inches) fibers; Woven fabric.

Properties of Polymer Matrix Composites are determined by:

Properties of the fibers; Orientation of the fibers; Concentration of the fibers; Properties of the matrix.

APPLICATIONS OF POLYMER MATRIX COMPOSITES

Polymer Matrix Composites (PMC) are used for manufacturing: secondary load-bearing aerospace structures, boat bodies, canoes, kayaks, automotive parts, radio controlled vehicles, sport goods (golf clubs, skis, tennis racquets, fishing rods), bullet-proof vests and other armor parts, brake and clutch linings.

Fiber glasses

Fiberglass is a common name of Polymer Matrix Composite materials reinforced by fine glass fibers. The reinforcing dispersed phase may be in form of either continuous or discontinuous glass fibers.

PROPERTIES OF FIBERGLASSES
Glass is widely used as a material for reinforcing fibers due to the following its properties:

Readily available and inexpensive material; Simple and inexpensive technology of preparation of continuous fibers from molten glass; High tensile strength, which may reach 600 ksi (4100 MPa); High corrosion resistance.

TYPES OF FIBERGLASSES
The types of glass used for fibreglasses are as follows:

E-Glass the most popular and inexpensive glass fibers. The designation letter E means electrical (E-Glass is excellent insulator). The composition of E-glass ranges from 52-56% SiO2, 12-16% A1203, 16-25% CaO, and 8-13% B203 S-Glass stronger than E-Glass fibers (the letter S means strength). S-Glass is used in military applications and in aerospace. S-Glass consists of silica (SiO2), magnesia (MgO), alumina (Al2O3). S+R-Glass the strongest and most expensive glass fibers of low diameter (half of that of E-Glass fibers). C-Glass corrosion and chemical resistant glass fibers. C-Glass fibers are used for manufacturing storage tanks, pipes and other chemical resistant equipment.

Glass fibers are manufactured from molten glass, from which glass monofilaments are drawn and then gathered to strands. The strands are used for preparation of different glass fiber products (yarns, rovings, woven fabrics, mats).

The most popular matrix materials for manufacturing fiber glasses are Thermo sets such as unsaturated polyesters (UP), epoxies (EP) and Thermoplastics such as nylon (polyamide), polycarbonate (PC), polystyrene (PS), polyvinylchloride (PVC). Fiberglass materials usually have laminate structure with different fibers orientations in the reinforcing glass layers. Various glass fibers orientations result in anisotropy of the material properties in the plane parallel to the laminates. Concentration of glass fibers in fiberglass is normally about 40% - 70%.

METHODS OF MANUFACTURING OF GLASS FIBER REINFORCED PMCs

GLASS Fiber Reinforced Polymers are manufactured by: ------------1.) Open mold processes, 2.) Closed mold processes and 3.) Pultrusion method.

Fiber glasses (Glass fibers reinforced polymer matrix composites) are characterized by the following properties:

High strength-to-weight ratio; High modulus of elasticity-to-weight ratio; Good corrosion resistance; Good insulating properties; Low thermal resistance (as compared to metals and ceramics).

APPLICATIONS COMPOSITES

OF

GLASS

FIBER

REINFORCED

POLYMER

MATRIX

Fiberglass materials are used for manufacturing: boat hulls and marine structures, automobile and truck body panels, pressure vessels, aircraft wings and fuselage sections, housings for radar systems, swimming pools, welding helmets, roofs, pipes.

Carbon Fiber Reinforced Polymer Composites

Carbon Fiber Reinforced Polymer (CFRP) is a Polymer Matrix Composite material reinforced by carbon fibers. The reinforcing dispersed phase may be in form of either continuous or discontinuous carbon fibers of diameter about 0.0004 (10 micron) commonly woven into a cloth. Carbon fibers are very expensive but they possess the highest specific (divided by weight) mechanical properties: modulus of elasticity and strength.

PROPERTIES OF CARBON FIBER REINFORCED PMCs

Carbon fibers are used for reinforcing polymer matrix due to the following properties:

Very high modulus of elasticity exceeding that of steel; High tensile strength, which may reach 1000 ksi (7 GPa); Low density: 114 lb/ft (1800 kg/m); High chemical inertness.

The main disadvantage of carbon (Graphite) fibers is catastrophic mode of failure (carbon fibers are brittle).

TYPES OF CARBON FIBER REINFORCED PMCs

The types of carbon fibers are as follows:

UHM (ultra high modulus). Modulus of elasticity > 65400 ksi (450GPa). HM (high modulus). Modulus of elasticity is in the range 51000-65400 ksi (350450GPa). IM (intermediate modulus). Modulus of elasticity is in the range 29000-51000 ksi (200350GPa). HT (high tensile, low modulus). Tensile strength > 436 ksi (3 GPa), modulus of elasticity < 14500 ksi (100 GPa). SHT (super high tensile). Tensile strength > 650 ksi (4.5GPa).

Carbon fibers are also classified according to the manufacturing method: 1. PAN-based carbon fibers (the most popular type of carbon fibers). In this method carbon fibers are produced by conversion of polyacrylonitrile (PAN) precursor through the following stages:

Stretching filaments from polyacrylonitrile precursor and their thermal oxidation at 400F (200C). The filaments are held in tension. Carbonization in Nitrogen atmosphere at a temperature about 2200 F (1200C) for several hours. During this stage non-carbon elements (O,N,and H) volatilize resulting in enrichment of the fibers with carbon. Graphitization at about 4500 F (2500C).

2. Pitch-based carbon fibers. Carbon fibers of this type are manufactured from pitch:

Filaments are spun from coal tar or petroleum asphalt (pitch). The fibers are cured at 600F (315C). Carbonization in nitrogen atmosphere at a temperature about 2200 F (1200C).

The most popular matrix materials for manufacturing Carbon Fiber Reinforced Polymers (CFRP) are thermosets such as epoxy, polyester and thermoplastics such as nylon (polyamide). Carbon Fiber Reinforced Polymers (CFRP) materials usually have laminate structure, providing reinforcing in two perpendicular directions.

METHODS OF MANUFACTURING OF CARBON FIBER REINFORCED PMCs

Carbon Fiber Reinforced Polymers (CFRP) are manufactured by: ------------4.) Open mold processes, 5.) Closed mold processes and 6.) Pultrusion method.

Carbon Fiber Reinforced Polymers (CFRP) are characterized by the following properties:

Light weight; High strength-to-weight ratio; Very High modulus elasticity-to-weight ratio; High Fatigue strength; Good corrosion resistance; Very low coefficient of thermal expansion; Low impact resistance; High electric conductivity; High cost.

APPLICATIONS COMPOSITES

OF

CARBON

FIBER

REINFORCED

POLYMER

MATRIX

Carbon Fiber Reinforced Polymers (CFRP) are used for manufacturing: automotive marine and aerospace parts, sport goods (golf clubs, skis, tennis racquets, fishing rods), bicycle frames.

Kevlar (aramid) fiber reinforced polymers

Kevlar is the trade name (registered by DuPont Co.) of aramid (poly-para-phenylene terephthalamide) fibers. Kevlar fibers were originally developed as a replacement of steel in automotive tires. Distinctive features of Kevlar are high impact resistance and low density.

PROPERTIES OF KEVLAR FIBERS REINFORCED PMCs

Kevlar fibers possess the following properties:

High Tensile strength (Five times stronger per weight unite than steel); High modulus of elasticity; Very low elongation up to breaking point; Low weight; High chemical inertness; Very low coefficient of thermal expansion; High Fracture Toughness (impact resistance); High cut resistance; Textile processibility; Flame resistance.

The disadvantages of Kevlar are: ability to absorb moisture, difficulties in cutting, low compressive strength.

TYPES OF KEVLAR FIBERS REINFORCED PMCs

There are several modifications of Kevlar, developed for various applications:

Kevlar 29 high strength (520000 psi/3600 MPa), low density (90 lb/ft/1440 kg/m) fibers used for manufacturing bullet-proof vests, composite armor reinforcement, helmets, ropes, cables, asbestos replacing parts. Kevlar 49 high modulus (19000 ksi/131 GPa), high strength (550000 psi/3800 MPa), low density (90 lb/ft/1440 kg/m) fibers used in aerospace, automotive and marine applications.

Kevlar 149 ultra high modulus (27000 ksi/186 GPa), high strength (490000 psi/3400 MPa), low density (92 lb/ft/1470 kg/m) highly crystalline fibers used as reinforcing dispersed phase for composite aircraft components.

Kevlar filaments are produced by extrusion of the precursor through a spinnert. Extrusion imparts anisotropy (increased strength in the lengthwise direction) to the filaments. Kevlar may protect carbon fibers and improve their properties: hybrid fabric (Kevlar + Carbon fibers) combines very high tensile strength with high impact and abrasion resistance. The most popular matrix materials for manufacturing Kevlar (aramid) Fiber Reinforced Polymers are Thermo sets such as Epoxies, Vinylester and Phenolics.

METHODS OF MANUFACTURING OF KEVLAR FIBER REINFORCED PMCs

KEVLAR Fiber Reinforced Polymers are manufactured by :------------1.) Open mold processes,

2.) Closed mold processes and

3.) Pultrusion method.

METHODS OF FABRICATIONS OF POLYMER MATRIX COMPOSITES

OPEN OPEN MOULD MOULD FABRICATI FABRICATI ON ON

Hand Lay-up Hand Lay-up

FABRICATI FABRICATI ON OF ON OF PMCs PMCs

CLOSED CLOSED MOULD MOULD FABRICATION FABRICATION POLTRUSION POLTRUSION

Compression Molding Compression Molding

Injection Molding Injection Molding Spray-up method Spray-up method Transfer Molding Transfer Molding Tape Lay-up Tape Lay-up

Filament Winding Filament Winding

Autoclave Curing Autoclave Curing

Open mold fabrication of Polymer Matrix Composites

Open Molding (Contact Molding) is the simplest method of fabrication of Polymer Matrix Composites. Open Molding is usually used for manufacturing large individual parts (swimming pools, boat bodies). Open Molding method is mostly used for fabrication Glass fiber reinforcing Polymers with polyester (sometimes epoxy or vinylester) matrix. The methods of open mold fabrication:

Hand Lay-up Spray-up method Tape Lay-up Filament Winding Autoclave Curing

Hand Lay-up
The most popular type of Open Molding is Hand Lay-up process. The Hand Lay-up is a manual, slow, labor consuming method, which involves the following operations:

The mold is coated by a release anti-adhesive agent, preventing sticking the molded part to the mold surface. The prime surface layer of the part is formed by applying gel coating. A layer of fine fiber reinforcing tissue is applied. Layers of the liquid matrix resin and reinforcing fibers in form of woven fabric, rovings or chopped strands are applied. The resin mixture may be applied by either brush or roll. The part is cured (usually at room temperature). The part is removed from the mold surface.

The disadvantages of the Hand Lay-up method are: low concentration of reinforcing phase (up to 30%) and low densification of the composites (entrapped air bubbles).

Spray-up
In Spray-up 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 Spray-up 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.

Tape Lay-up
In this method layers of prepreg (reinforcing phase impregnated by liquid resin) tape are applied on the mold surface by a tape application robot.

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.

Autoclave Curing
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.

Closed mold fabrication of Polymer Matrix Composites

Closed Mold methods are used when mass production of identical parts with both smooth surfaces is required. Closed Molding methods are used for fabrication of Fiber glasses, Carbon Fiber Reinforced Polymer Composites and Kevlar fiber reinforced polymers.

Compression Molding Injection Molding Transfer Molding

Compression Molding
Compression Molding is a Closed Mold process in which a molding charge is squeezed into a preheated mold taking a shape of the mold cavity and performing curing (cross-linking) due to heat and pressure applied to the material. The method uses a split mold mounted in a hydraulic press Compression Molding process involves the following steps:

A pre-weighed amount of a polymer (commonly thermosetting resin) mixed with chopped reinforcing fibers, hardening agent, anti-adhesive agent and pigment (charge) is placed into the lower half of the mold.

The charge may be in form of powders, pellets, putty-like masses or pre-formed sheets. The charge is usually preheated prior to placement into the mold. Preheated polymer becomes softer resulting in shortening the molding cycle time.

The upper half of the mold moves downwards, pressing on the charge and forcing it to fill the mold cavity.

The mold, equipped with a heating system, provides curing (cross-linking) of the polymer matrix (if thermosetting resin is processed).

The mold is opened and the part is removed from it by means of the ejector pin.

Compression Molding cycle time is about 1-6 min, which is longer than Injection Molding cycle. The method is suitable for mass production of flat or moderately curved parts.

Injection Molding

Injection Molding is a Closed Mold process in which molten polymer (commonly thermoplastic) mixed with very short reinforcing fibers (10-40%) is forced under high pressure into a mold cavity through an opening (sprue). Polymer-fiber mixture in form of pellets is fed into an Injection Molding machine through a hopper. The material is then conveyed forward by a feeding screw and forced into a split mold, filling its cavity through a feeding system with sprue gate and runners. Screw of injection molding machine is called reciprocating screw since it not only rotates but also moves forward and backward according to the steps of the molding cycle. It acts as a ram in the filling step when the molten polymer-fibers mixture is injected into the mold and then it retracts backward in the molding step. Heating elements, placed over the barrel, soften and melt the polymer. The mold is equipped with a cooling system providing controlled cooling and solidification of the material. 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.

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.

Transfer Molding
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 method is used primarily for molding Polymer Composites with thermosetting resin matrices, but some thermoplastic parts may also be produced by Transfer Molding. 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 (thermo sets) and Injection Molding ram (plunger), filling the mold through a sprue. Transfer Molding process involves the following steps:

The mold cavity is filled with preformed reinforcing fibers. A pre-weighed amount of a polymer mixed with additives and fillers (charge) is placed into the transfer pot.

The charge may be in form of powders, pellets, putty-like masses or pre-formed blanks. The charge is heated in the pot where the polymer softens.

The plunger, mounted on the top plate, moves downwards, pressing on the polymer charge and forcing it to fill the mold cavity through the sprue and impregnate the fibers.

The mold, equipped with a heating system, provides curing (cross-linking) of the polymer (if thermo set is processed).

The mold is opened and the part is removed from it by means of the ejector pin.

If thermosetting resin is molded, the mold may be open in hot state cured thermo sets maintain their shape and dimensions even in hot state. If thermoplastic is molded, the mold and the molded part are cooled down before opening.

The scrap left on the pot bottom (cull), in the sprue and in the channels is removed. Scrap of thermosetting polymers is not recyclable.

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.

Pultrusion
Pultrusion is an automated, highly productive process of fabrication of Polymer Matrix Composites in form of continuous long products of constant cross-section. A scheme of the process is presented on the picture:

Pultrusion process involves the following operations:

1. 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. 2. Guide plates collect the fibers into a bundle and direct it to the resin bath. 3. 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. 4. The wet fibers exit the bath and enter preformer where the excessive resin is squeezed out from fibers and the material is shaped. 5. The preformed fibers pass through the heated die where the final cross-section dimensions are determined and the resin curing occurs. 6. The cured product is cut on the desired length by the cut-off saw.

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 glasses, Carbon Fiber Reinforced Polymer Composites and Kevlar fiber reinforced polymers.

APPLICATIONS OF POLYMER MATRIX COMPOSITES (PMC)

1. AUTOMOBILE APPLICATIONS
2. AEROSPACE APPLICATIONS

3. ELECTRICAL APPLICATIONS 4. ELECTRONICS APPLICATIONS 5. MARINE APPLICATIONS 6. SPORTS APPLICATIONS 7. POLYMER PIPING SYSTEMS 8. NANO COMPOSITES

References: ----------1. Dr. HK Shivanand & Babu Kiran; Composite Materials , Asian Books Publications (2010) 2. D Haul & Clyne; An Introduction To Composite Materials , Cambridge University Press (2008) 3. PMC Materials at WWW.SUBSTECH.COM