Z.SHANTI KIRAN NAGENDRA PRASAD SURESH.

J

JAISON JACOB
CONTENT

1.RESINS(POLYMERS).
2.FIBERS.
3.MANUFACTURING PROCESSES.
4.APPLICATIONS.
POLYMERS
WIDE VARIETY AVAILABLE
SELECTION BASED ON:
PHYSICAL AND MECHANICAL PROPERTIES OF
PRODUCT
FABRICATION PROCESS REQUIREMENTS

TYPES OF RESINS

THERMOSET
THERMOPLASTIC

THERMOSET
POLYESTER
VINYL ESTER
EPOXY
PHENOLIC
POLYURETHANE

THERMOPLASTIC
ACETAL
ACRYRONITRILE BUTADIENE STYRENE (ABS)
NYLON
POLYETHYLENE (PE)
POLYPROPYLENE (PP)
POLYETHYLENE TEREPHTHALATE (PET)

THERMOSET ADVANTAGES
THERMAL STABILITY
CHEMICAL RESISTANCE
REDUCED CREEP AND STRESS RELAXATION
LOW VISCOSITY- EXCELLENT FOR FIBER
ORIENTATION

THERMOPLASTIC ADVANTAGES
ROOM TEMPERATURE MATERIAL STORAGE
RAPID, LOW COST FORMING
REFORMABLE

POLYESTERS
LOW COST
EXTREME PROCESSING VERSATILITY
MAJOR USES:
Transportation
Construction
Marine


VINYL ESTER
SIMILAR TO POLYESTER
EXCELLENT MECHANICAL & FATIGUE PROPERTIES
EXCELLENT CHEMICAL RESISTANCE
MAJOR USES:
Corrosion Applications - Pipes, Tanks, & Ducts

EPOXY
EXCELLENT MECHANICAL PROPERTIES
GOOD FATIGUE RESISTANCE
LOW SHRINKAGE
GOOD HEAT AND CHEMICAL RESISTANCE
MAJOR USES:
FRP Strengthening Systems
FRP Rebars
FRP Stay-in-Place Forms

PHENOLICS
EXCELLENT FIRE RETARDANCE
LOW SMOKE & TOXICITY EMISSIONS
HIGH STRENGTH AT HIGH TEMPERATURES
MAJOR USES:
Mass Transit - Fire Resistance & High Temperature
Ducting

POLYURETHANE
TOUGH
GOOD IMPACT RESISTANCE
GOOD SURFACE QUALITY
MAJOR USES:
Bumper Beams, Automotive Panels

Physical Properties of Thermosetting
Resins Used in Structural Composites
Resin
Type
Density
(kg/m
3
)
Tensile
Str.
(MPa)
Elong.
(%)
E-
Mod.
(GPa)
Long.T
erm
t ,(C)
Polyester 1.2 50-65 2-3 3 120
Vinyl
Ester
1.15 70-80 4-6 3.5 140
Epoxy 1.1-1.4 50-90 2-8 3 120-
200
Phenolic 1.2 40-50 1-2 3 120-
150


MAN-MADE FIBERS
ARAMID
BORON
CARBON/GRAPHITE
GLASS
NYLON
POLYESTER
POLYETHYLENE
POLYPROPYLENE

FIBERS
Generally circular in cross-section, but can also be in the form
of tubular, rectangle, hexagonal.
Fibers used can be either continuous or discontinuous
Continuous fibers : are very long; in theory, they offer a
continuous path by which a load can be carried by composite
material.
Discontinuous fibers : are short lengths.
FIBER PROPERTIES
DENSITY (g/cm
3
)
1.38
1.59
1.99
1.99
2.76
8
0 2 4 6 8 10
Aramid
Carbon
S-Glass
E-Glass
Alum
Steel
FIBER PROPERTIES
TENSILE STRENGTH
500
525
530
625
20
60
0 200 400 600 800
E-Glass
Aramid
Carbon
S-Glass
Steel
Alum
FIBER PROPERTIES
STRAIN TO FAILURE
1.4
2.8
4.8
5
0.2
0.16
0 1 2 3 4 5 6
Carbon
Aramid
E-Glass
S-Glass
Steel
Alum
FIBER REINFORCEMENT
GLASS
MOST COMMON FIBER USED
HIGH STRENGTH
GOOD WATER RESISTANCE
GOOD ELECTRIC INSULATING PROPERTIES
LOW STIFFNESS

GLASS TYPES
E-GLASS
S-GLASS
C-GLASS
ECR-GLASS
AR-GLASS

FIBER REINFORCEMENT
ARAMID (KEVLAR)
SUPERIOR RESISTANCE TO DAMAGE (ENERGY
ABSORBER)
GOOD IN TENSION APPLICATIONS (CABLES,
TENDONS)
MODERATE STIFFNESS
MORE EXPENSIVE THAN GLASS

CARBON
GOOD MODULUS AT HIGH TEMPERATURES
EXCELLENT STIFFNESS
MORE EXPENSIVE THAN GLASS
BRITTLE
LOW ELECTRIC INSULATING PROPERTIES

ADVANTAGES AND DISADVANTAGES
OF REINFORCING FIBERS
Fiber Type Advantages Disadvantages
E-Glass, S-Glass High Strength,
Low Cost
Low Stiffness,
Fatigue
Aramid High Strength,
Low Density
Low Compr. Str.,
High Moisture
Absorption
HS Carbon High Strength and
Stiffness
High Cost



Fiber Terminology
FILLERS
To improve performance
Reduce the cost of a composite.
Reduce mould Shrinkage.
Surface smoothness.
Crack resistance.
Enhance compressive strength.
Different fillers used:
Marble dust.
Silicon dioxide.
Alumino-silicate sand.
Calcium Carbonate
Kaolin
Alumina Trihydrate
Mica Feldspar
Wollastonite


ADDITIVES
A constituent component that may be added to the composite
matrix to modify its properties and in general, enhance its
performance.
Additives include catalysts, colorants, flame retardants and
other ingredients that expand and improve the capabilities of
the matrix.
Additives like antimony trioxide and alumina trihydrate,
improve the fire retardancy of frp.
FEATURES OF FRP:
High strength-to-weight ratio.
High modulus-to-weight ratio.
Low specific gravity.
Good fatigue strength.
Good corrosion resistance, although polymers are soluble in
various chemicals.
Low thermal expansion, leading to good dimensional stability.
Significant in anisotropy properties.
MANUFACTURING PROCESSES OF FRP
Hand Lay-up/Spray-up
Resin Transfer Molding (RTM)
Compression Molding
Injection Molding
Reinforced Reaction Injection Molding (RRIM)
Pultrusion
Filament Winding
Vacuum Assisted RTM (Va-RTM)
Centrifugal Casting

Manufacturing Processes
1. Hand Lay-up Process:
Matrixes/Resins are impregnated by hand into fibers
which are in the form of chopped strand mat woven or
bonded fabrics. This is usually accomplished by rollers or
brushes, with an increasing use of nip-roller type
impregnators for forcing resin into the fabrics by means of
rotating rollers and a bath of resin.
Laminates are left to cure under standard atmospheric
conditions.
ADVANTAGES
Corrosion Resistant
Low maintenance requirement
Impact resistance
Non-conductive and Non metallic
Fire Retardant
High strength-to-weight ratio
Reduced installation time and cost



DISADVANTAGES
High Cost.
Creep and Shrinkage.
Potential for Environmental Degradation (Alkalis' Attack,
UV Radiation Exposure, Moisture Absorption, etc).
Global and Local Buckling
Aerodynamic Instability With Lightweight
Requires Highly Trained Specialists
Limited Joining and Connection Technology (Adhesive
joints, fasteners)


2.Spray Lay up
Fiber is chopped in a hand-held gun and fed into a spray of
catalyzed resin directed at the mould. The deposited materials
are left to cure under standard atmospheric conditions.
Materials Options:
Resins: Primarily polyester.
Fibers: Glass roving only.
Cores: None. These have to be incorporated separately.
Advantages:
i) Large and complex items can be produced.
ii) Design flexibility.
iii) Low cost tooling.
Disadvantages:
i) Low volume process.
ii)Quality is related to the skill of operator.
iii) Product uniformity is difficult.
Typical Applications:
Simple enclosures, lightly loaded structural panel for caravan
bodies, truck fairings, bathtubs, shower trays.
APPLICATIONS
Simple enclosures,
lightly loaded structural panel for caravan bodies,
truck fairings,
bathtubs,
shower trays.

3.Filament Winding
This process is primarily used for hollow, generally
circular or oval sectioned components, such as pipes and
tanks.
Fiber tows are passed through a resin bath before being
wound onto a mandrel in a variety of orientations,
controlled by the fiber feeding mechanism, and rate of
rotation of the mandrel.
Materials Options: Resins: i.e. epoxy, polyester, vinyl ester
and phenolic.
Fibers: The fibers are used straight from a creel and not
woven or stitched into a fabric form.
Cores: Any, although components are usually single skin.

ADVANTAGES:
This can be a very fast and therefore economic
method of laying material down.
Versatility is obtained.
Fiber cost is minimized since there is no secondary
process to convert fiber into fabric prior to use.
Structural properties of laminates can be very good
since straight fibers can be laid in a complex pattern to
match the applied loads.
DISADVANTAGES:
The process is limited to convex shaped components.
There is poor external surface.
Mandrel costs for large components can be high.
Winding at low angles is difficult .
APPLICATIONS OF FRP
New Bridge Structures
Enclosures
Bonded Steel Plates
Bonded Carbon Laminates
Cables
Rope
Rods
Anchors
Research
Manufacturing
STORCHENBRUCKE (Stork Bridge) -
Switzerland
First Cable-Stayed Road Bridge; 406 ft Length
with Pylon Height of 125 ft
Construction in 1994-96; 2 of 24 CFRP Cable
Stays
SECOND SEVERN ENCLOSEURE
SYSTEM - UK
Construction 1993
Bridge Bottom Soffit Enclosure System
40 psf Design Load With L/120 Deflection
FRP INDUSTRIES IN INDIA.
THANKYOU