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PROCESSING
CBB 4423
POLYMER COMPOSITE
Part 1
PRESENTATION OUTLINE
Part 1
Introduction
to Polymer composite
Classification
Thermoplastic based (matrices)
Thermoset based (matrices)
Interphase adhesion
Characterizing the effectiveness of the
reinforcement
Part ii -
INTRODUCTION
COMPONENTS IN A COMPOSITE MATERIAL
INTRODUCTION
FUNCTIONS OF THE MATRIX MATERIAL
(PRIMARY PHASE)
TERMINOLOGY/CLASSIFICATION
Composites:
-- Multiphase material w/significant
proportions of each phase.
woven
fibers
Matrix:
-- The continuous phase
-- Purpose is to:
- transfer stress to other phases
- protect filler/fiber phases from environment
0.5 mm
cross
section
view
Dispersed phase:
-- Purpose: enhance matrix properties.
increase E, y, TS, creep resist.
0.5 mm
Reprinted with permission from
D. Hull and T.W. Clyne, An Introduction
to Composite Materials, 2nd ed.,
Cambridge University Press, New York,
1996, Fig. 3.6, p. 47.
POLYMER COMPOSITE
C o m p o s it e s
P a r t ic le - r e in fo r c e d
L a rg e p a r t ic le
D is p e r s io n s tre n g th e n e d
F ib e r - r e in fo r c e d
C o n t in u o u s
( a lig n e d )
D is c o n t in u o u s
(s h o rt)
A lig n e d
Nanocomposite
S tru c tu ra l
R a n d o m ly
o r ie n t e d
L a m in a t e s
S a n d w ic h
p a n e ls
Performance
Or Engineering
polymer
Commodity
Polymer
Material
Density
(kg/m3)
Tensile
Strength
(MN/m2)
Flexural
Modulus
(GN/m2)
%
Elongation at
break
Price*
Nylon 66
1140
70
2.8
60
3.9
PEEK
1300
60
3.8
42
Polysulfone
1240
70
2.6
80
11
PET
1360
75
70
Polycarbonate
1150
65
2.8
100
4.2
Polyethersulfone
1370
84
2.6
60
13.3
Polyimide
1420
72
2.5
150
polypropylene
905
33
1.5
150
Polystyrene
1050
40
1.5
1.1
LDPE
920
10
0.2
400
0.83
HDPE
950
32
1.2
150
1.1
PVC (rigid)
1400
50
80
0.88
Particulate / Spherical
CaCO3
Fibrous
Acicular
Wollastonite
Glass fibres
Lamellar,
Talc,
Mica,
Clay
NANOCOMPOSITE
Weakinterface
ADVANTAGE OF NANOCOMPOSITE
Flame Retardant -
PP COMPOSITE
articles
Appliances
(washing machine parts,
refrigerator parts)
Furniture
(moulded chairs, tables and
benches)
Automobiles
(bumpers, IP, interior trims,
door trims)
Moulded luggage
COMPOSITES: FIBER-BASED
PP or EPOXY RESIN
PERFORMANCE IMPROVEMENT ?
Fibers or fillers and polymer do not react, but the polymer
must adhere very well to the fiber for strength.
INTERFACE ADHESION
Si203
CaCO3
REINFORCEMENT-MATRIX INTERFACE
The
INTERFACE ADHESION
OH
A
O
---
=C
Hydrogen Bonding
l
2
O
3
155
155
And
And consequently
d 2
A
dl
2
(1)
d 2 l
V
4
A 2 4
V l d
(2)
A 2
V V
1
3
23
2a
1
3
a = l/d
(3)
Platelet/flake/lamellar
Fibre
20
15
10
5
0
0.01
0.1
a (log scale)
10
100
Example1
Glass particles for reinforcement are available in various forms. Rank
the following in order of their expected efficiencies as reinforcing particles.
(a)
(b)
(c)
(d)
Void
In Practice composite materials contain voids which comprised trapped
Air, solvent etc.
A void is a source of weakness.
A void content > 2% indicates poor fabrication
A void content < 0.5% indicates high-class fabrication
Give the exact composite density and with
f, f, and m known the fraction of voids can be calculated.
The fraction of voids can be calculated from the difference between experimental
and theoretical densities of a particular composite.
Example 2:
Composite materials to be prepared with the following compositions (by volume)
Polypropylene reinforced by 20 v% glass fibre;
Epoxy reinforced by 25 v% carbon fibre and 25v% kevlar fibre
In each case , find the mass of each constituent required per unit mass of composite.
The densities (in kg/m3) are glass fibre 2540; polypropylene 900;
carbon fibre 1790; kevlar 1450; and epoxy 1300
Solution:
(a)First find the density of the composite:
f f 1 f m
Part II
Two
EXTRUSION
WORKABILITY
Pultrusion
Continuous fibers pulled through resin tank, then preforming die & oven to
cure
This is the composite form most widely used for structural applications