Clculo y diseo de

estructuras

Laboratory exercise:
Manual fabrication of a short fiber epoxy-glass composite
laminate and study of the effect of the fibers length at the
mechanical characteristics of the laminate. Fabrication of
an hybrid epoxy-glass-wood composite laminate and study
of the effect of the percentage of the wood fibers to the
mechanical characteristics of the laminate.

Proposed by: Stamatina Giannakoulakou

On: 23/06/2014

TERRASSA , 2014
1 Fundamental theory
1.1 Composite Materials
Composite materials, according to their exact definition, are structural
materials that consist of two or more combined constituents that are
combined at a macroscopic level (a visible to the naked eye scale) and are
not soluble in each other. The constituents may have different physical or
chemical properties, and when are combined they produce a material with
different characteristics from the individual components. The individual
components remain separate and distinct within the finished structure.
Two are the main categories of the constituent materials of the
composites, the matrix and the reinforcement. The matrix phase, than can
be a polymer, metal or ceramic material, surrounds and supports the
reinforcements, that can be fibers, particles of flakes of specific materials
and their role is to impart their special mechanical and physical properties
to enhance the properties of the matrix. In a simpler way we could say
that the matrix holds the reinforcement to form the desired shape while
the reinforcement improves the overall mechanical properties of the
matrix. When designed properly, the new combined material exhibits
better strength than would each individual material.
The most common material that is used for matrices are the resins, which
are polymer-based substances. There is a grand variety of resins available,
the choice of whom depends on the specific characteristics we want the
composite to have. The most commonly used resins are polyester, vinyl
ester and epoxy, among other. Every one of the different resins materials
may have different color, viscosity, resistance, hardness etc.
The reinforcement materials are often fibers or ground minerals. Is the
part of the composite that will provide strength and rigidity and will
impede propagation of possible cracks on the material. Its the
reinforcement that gives to the composite the most important overall
properties. As reinforcements are used fibers, particles, flat flakes or
fillers, but what is most widely used are the fibers. The fibers can be
divided in two big groups, the short or random fibers, and the long or
continuous fibers. The long reinforced fibers are used for composites in
layers or laminates and have a wide use, whereas the short ones in most
specific cases. Most popular reinforcement fibers are the glass fibers, the
carbon fibers, natural cellulose fibers such as paper and wood, and high
strength polymers.

1.2 Manufacturing
When it comes to manufacturing, there are several ways that we can
fabricate composite materials, that are divided in two big groups, the open
molding processes, and closed molding processes. In the first type of
manufacturing the laminate produced is exposed to the atmosphere
during its fabrication, while in closed molding the composite is fabricated
between two sides of a mold, usually inside a vacuum bag, so it has no
contact with the atmosphere while its being fabricated. There are
different types of fabrication in every one of the two groups, for example:
Open molding: Hand lay-up, Spray Up, Filament Winding
Closed Molding: Compression Molding, Resin transfer Molding, Vacuum
Bag Molding, Centrifugal Casting, Continuous Lamination.
The selection of the method that is going to be used for the fabrication of
the composite material depends on a number of factors such as cost,
materials, size but the most important factor is the volume of production.
Based on that, we will use the Hand Lay-Up or the Vacuum Bag molding
method for low volume production, Filament Winding or Resin Transfer
Loading for medium Volume production and Compression Molding or
Continuous Lamination for high volume production of composite materials.
The purpose of this exercise is to produce a composite material with the
simplest method of low volume production. The process is described
below.

1.2.1 Hand Lay up Method

This method is an open molding method, which means the material
fabricated is in contact with the atmosphere during its production, that is
suitable for a wide variety of composites that are used in vehicles,
vessels, housing, etc, covering all sizes from very small to very large.
First, we have to coat the mold cavity with polyvinyl alcohol or a nonsilicon wax, to aid component release. Then, a gel coat needs to be
sprayed on the surface of the mold. The gel coat is a pigmented polymer
resin that gives a glossy high quality finish to the product and a smoother
surface, for aesthetical and environmental purposes. After the gel goat has
been cured sufficiently, we place the fiber glass reinforcement manually
on the mold. We continue with the resin, that is poured to the mold over
the fibers, and then is rolled to with special rollers, to ensure complete
wetting of all the fibers and removal of possible air bubbles. The resin is
then left to cure at room temperature with the use of an accelerator and a
catalyst. We could speed up the procedure and avoid the use of a catalyst
if we cure the resin in elevated temperatures.

This method is widely used for many years, is simple, without high costs in
tools and serves a wide choice of materials. Some of the main
disadvantages of this method are the health considerations as the small
molecular weights of the roll up resins can be more harmful due to the
easier penetration to the workers respiratory system. Also, as it is a
manual method, the final result depends on the skills of the worker.
Furthermore, the resins have to have low viscosity in order to be worked
with the hand easily and be spread on all the fibers.

0-1 Hand Lay-Up method

0-2 Workers rolling up the resin

1.2.2 Epoxy Resins

The epoxy resins are very widely use in the fabrication of composites, as
we have mentioned before. Its a solution that doesnt have a big cost
(although bigger than the polyester resins) with good mechanical results.
They are considered medium temperature resins, since they maintain their
properties to temperatures up to 120 grades of Celsius.
The epoxy resin consists of two substances, the component A and
component B, that is the liquid resin reactive and the curing agent,

respectively. The liquid resin incorporates all the additives that are
necessary for the polymerization of the epoxy, that will give us a solid
matrix with all the desired properties that a matrix of a composite should
have (mechanical, physical and chemical properties).
The fabrication of the epoxy matrix requires a certain temperature, that is
different according with the use of the composite material that is
produced. The resins for the laminates fabrication should be cured at
room temperature, with no further need of heat.

1.2.3 Glass fiber

The fiber glass is one of the most commonly used fibers for the production
of composite materials. Its low cost and its very good mechanical, thermal
and electrical characteristics make it a perfect choice. Also, glass fibers
are compatible with organic matrices. There are different types of glass
fibers, according to their chemical composition.

1.3 Hybrid composite materials

Lately, another type of composite materials has made its appearance, the
hybrid composites. The hybrid composites combine two different kinds of
reinforcement, method which gives to the final product the properties of
the materials. With this way we have a composite with better mechanical
characteristics.

2 Realization of the experiment

2.1.1 Objective
Objective of the experiment is to get a more profound view of the
fabrication process of the composite materials and study their mechanical
properties. The mechanical properties of the composite materials may
vary according to their constructive characteristics, such as the length of
the fiber, the percentage of the fiber on the final product, and the
directions of the fibers. More specifically, on this experiment you are
asked to study the effect of the fiber length on the mechanical properties
of the epoxy- short fiber glass composites, and how the mechanical
properties are altered in the case of an hybrid composite, in which we
have added wood fibers in different percentages.

2.1.2 Fabrication of the laminates

You are asked to fabricate 8 different composite laminates, with the
method of Hand Lay-up, as it is described at the paragraph 2.1.

Part 1
2.1.3 Laminate molds
We will use rectangular molds, with dimensions 30x15x3 cm, that are
available on the laboratory. The molds are already sprayed with the
special gel that gives a smoother finish, and has left to be cured.
2.1.4 Preparation of the fibers
We will fabricate 8 different types of laminates for the needs of our
experiments, 2 with short glass fibers, 2 with longer short glass fibers and
4 with longer short glass fibers and wood fibers (hybrid composites).
The percentage of the fibers on the composite is another factor that can
affect the composites properties. Studies have shown that the more
percentage of fibers there is in the laminate, the better the qualities of the
product get. The fabrication of the laminates in our experiment will be
realized with a 60% of fibers. In the case of the hybrid composite
laminates we will study the effect of the addition of organic fibers in the
composite. We will need 2 laminates with a percentage of 50% of glass
fiber and 10% of wood fiber, and 2 more with 30% of glass fiber and 10%
of wood fiber.
We will study the effect of the length of the fibers at the composites
properties. It is already known that continuous fibers give to the composite
more rigidity and resistance. In our case we will study how the length of
the short fibers affect those properties. For this reason you are asked to
cut the glass fiber in small pieces of two dimension groups: a) pieces of a
length between 0,5 and 1,5 cm and b) pieces of a length between 1,5 and
3 cm. Also, you are asked to cut the wood fibers in pieces of a length
between 1,5 and 3 cm too.
Divide the different sizes of the glass fibers and the wood fibers in
different piles.

2.1.5 Preparation of the resin

The two components of the epoxy resin, A and B, will have to be mixed in
a proportion 100 A to 16 B. For the production of each laminate we will
need 50 gr of epoxy resin. It is important to use gloves and masks
throughout all the procedure. Mix the correct quantities of the 2
substances and stir well until the mixture is uniform.

2.1.6 Preparation of the laminate

Each laminate consists of a different number of laminas. We will produce
laminates that consist of 5 laminas.
Put the fibers in the mold. Be sure to put the correct quantity of fibers
according to the laminates we want to fabricate. After the fibers pour the
resin mixture we have prepared. This phase has to be completed in 30
minutes because in greater times the viscosity of the resin is getting
bigger and the fibers are not impregnated well. Use the special rolls
available at the laboratory, to help you spread the product throughout all
the area of the mold and be sure there will be no air bubbles left. Apply
the special mat that will divide the laminas. Continue the fibers. This
procedure has to be repeated 4 more times, so we will have a laminate
that will be consisted of 5 laminas.
Let the product cure in room temperature. This is a procedure that can
take several hours, approximately 24 hours. (The experiment will have to
be completed in the following session).
2.1.7 Final product
The composite is now ready. With caution try to remove each composite
from the mold. Check each laminate for cracks or defects by observation.
Bend each laminate to ensure the minimal rigidity.

Part 2
2.1.8 Mechanical testing
We will study how the 4 different groups of composite laminates behave
when tensile and flexion stress are applied. The flexural tests will be
performed on the flexural test machine, according to the ASTM test
method D-790. The tensile properties of each laminate will be performed
at the tension test machine according to the ASTM test method D-638.
You are asked to define four parameters of the laminates: the modulus
of rapture, the modulus of elasticity (flexural test), the tensile
modulus, and the ultimate tensile strength (tensile test) between
the following laminates:

Laminate with short and laminate with long fibers (4 tests)

Hybrid laminate with 10% of wood fiver and 30% of wood fiber (4
tests)

You can find the exact instructions for the realization of the test on the
ASTM documentation.
2.1.9 Results
Present the results on a table (the modulus of rapture, the modulus
of elasticity, the tensile modulus, and the ultimate tensile strength,
for every one of the laminates)

Present the stress-strain curve of the tests. (the machines send the
results real time to the computer).
How does the length of the fibers affect the mechanical behavior of
the laminate? Is the relation lineal ?
How does the extra wooden fibers affect the mechanical behavior of
the laminate? Which percentage of extra wood fibers gives to the
laminate better mechanical behavior?
Do some internet research about the hybrid composite materials.

2-3 Tensile strees testing machine

2-4 Flexure stress testing machine