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INTRODUCTION
Composite materials have been used since biblical times when chopped
straw was added in bricks to make building materials. The modern composite materials
age began with the introduction of particular fibrous reinforcement materials into
thermosets phenollics in 1900’s. The first GRP was made in 1942. Reinforcement
thermoplastic were virtually non-existent in early 1950’s but by 1990’ s reinforcement
thermoplastic represented about one fourth of the total reinforced plastics & composite
materials.
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Thermoplastic Composites
COMPOSITE MATERIALS.
Thus composite material can be defined as multiphase material, formed by
combination of materials differing in composition which remain bonded together, but
retain their identities & properties, without going into any chemical reaction.
The composite material don’t dissolve but they are completely merge with
each other. They maintain an interface between each other & act in concrete to provide
improved specific or synergistic characteristic not obtainable by any of the original
component acting singly.
CLASSIFICATION :
COMPOSITE MATERIALS
The classification based on the plastic matrix are thermoplastic & thermosetting.
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Thermoplastic Composites
MATRIX
REINFORCEMENT
FILLERS
MATRIX :- It is also called as binder. The phase that receives the inserts in the phase
composition is the continuous phase & is called as matrix.
REINFORCEMENT :- These are materials which basically gives strength, stiffness &
other mechanical properties to composite materials.
FIBER-MATRIX INTERPHASE
The interphase between the fiber and matrix can be easily identified ,it
is the behaviour and property of interphase that generally control the properties of
composites. The main role of interphase is to transmit and distribute the load on matrix to
the reinforcement.
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Thermoplastic Composites
MATRIX
Definition – The phase that receive the inserts in phase composition is continuous phase &
is called as matrix. It is also called as binders. The matrix material employed for
fabrication of composites material are usually polymer & commonly called as Resin.
Types - The materials used for the matrix are plastic, rubbers, ceramic & metals.
Plastic matrix based composite materials now constitute more than 95% of
all composite materials in use today. Both Thermoplastic & Thermosetting materials are
used as matrix materials.
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Thermoplastic Composites
These polymer has excellent properties that are required for matrix or binders this are.
Mechanical Properties:
Chemical properties:
Chemical stability.
Applications –
These PE is used in pipe which has been used for transportation various
kinds of fluids because of its high resistance to corrosive materials.
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Thermoplastic Composites
This polymer has excellent properties that are required for matrix or binders
these are :
Mechanical properties :
Chemical Properties :
Chemical stability.
POLYPROPYLENE
Polymerisation of propylene is carried out in presence of suitable
heterogeneous catalyst to form polypropylene.
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Thermoplastic Composites
Mechanical Properties
Chemical Properties
Applications
NYLONS – 6 OR PERLON – L
A polyamide closely related is Nylon known as Perlon – L or Nylon – 6 is
based on a polymeric fibre form only one constituent caprolactum NH – (CH)5 – CO
giving polymer ( − (CH 2 ) 5 CO − NH − ) n it is prepared by prolong heating of ω – amino
caprolactum at 250 – 278 C. Nylon is often used in thermoplastic composite because of
presence of saturation or double bonds in its structures.
Mechanical Properties :
Chemical Properties
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Thermoplastic Composites
Applications
POLYPHENYLENE SULPHIDE
These materials have been prepared by polymerisation at p-
halothiophenoxide metal component both in solid state and in solution.
flame resistance
chemical resistance
electrical resistance.
Applications
This polymer with its very high heat & flame resistance & chemical &
electrical resistance characteristic found its application in exhaust gas return value
carburetor parts, ignition plates, Motor housing.
REINFORCEMENT
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Thermoplastic Composites
Definitions :- It is materials which gives strength, stiffness & other mechanical properties
to composite materials.
The reinforcement increases the ratio of strength to density & stiffness to density.
It also increase resistance to corrosion fatigue, creep & repturs stress & reduce cost.
TYPES OF REINFORCEMENTS
Reinforcement can be classified in 5 types.
1. Mineral reinforcement :- The mineral fillers most commonly employed are CaCo3,
Silica, mica tale clay, alumina etc.
3. Sandwich Reinforcement
Although plastics are electrical & thermal insulators. They can be made conductor by
introducing metallic or conductive fillers.
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Thermoplastic Composites
Inorganic or organic fibers such as carbon, glass, aramides etc have been widely used with
plastic mainly to improve mechanical strengths & tensile modulus.
Now we will discuss some of the fibres used in reinforcements one by one.
GLASS FIBRE.
Glass fibre are the oldest form of strength fibre used in composite structure
materials. Continuous fibre are made by a growth extension process. In air craft aerospace
& military application in which strength to wt. Ratio are critical constitute the fastest
growing market for glass fibre reinforced materials.
The glass fibre for reinforcement is available in several forms like fibres
rovings, chopped, strands, yarns & mate.
The principle ingredients in all glass fibres is silica and other oxide. The Na2O & K2O
content in glass fibre is quite low which give them a better corrosion resistance to water as
well as higher surface resistivity.
The glass fibres are availables in no. of grades for reinforcement purpose.
A glass – cost effective, for general purpose. Easily attacked by moisture & alkaline.
E glass –these has high level electrical resistivity, surface resistivity & forming.
D glass – highest structural resistance properly when stiffness is more important than
strength.
Application : These found application in pressure bottles, automobile bodies, for tubing &
pipes & in sportsgoods.
CARBON FIBRE
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Thermoplastic Composites
Now a days carbon fibres finds its own place in the composite materials
where weight reduction are valuable.
Many techniques have been tried for producing carbon fibre. All of them
involve the heat treatment of carbon containing raw material usually in form of polymer
fibre & carbonising them . Three raw materials generally employed for production of
commercial products these are rayon, acryllic, & PAN fibre & fibre span pitch.
Applications – High temperature property of carbon fibre are being put to use in pump
packing, bearing & breaks or breaks disc materials.
BORON FIBRES
Boron fibre is also immerging as the principle constituents or high
characteristic properties contain fibre.
This are prepared by reduction of boron tri-chloride in chemical vapour deposition process
on hot tungsten or graphite filament.
Advantages . 1. these are of low density, high tensile strength, high modulus fibres.
Disadvantages – The amorphous boron fibre has excellent properties but process is very
costly.
Applications –These are highly suitable for aerospace industries, Automobile industries.
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Thermoplastic Composites
KEVLAR FIBRE
Now one of the immerging member in reinforcement fibre family is kevlar.
These are introduce in 1972 commercially to replace steel in radial tyres.
These are low density strength armid fibre. Designed for ballistic
protection slash & cut resistance, ropes, cables & coating fabrics for flashable &
architechral fabrics. It is also used in production such as brakes & clutches.
Resistance to stretch.
Application: These are finding broad application in belts of radials car tyres, car cases,
marine, automobile & other industrial applications.
JUTE
Commercially jute is the most important vegetable fibre other than cotton.
About 60% of world jute is produce in India.
These are cheap & easily available fibre. After the retting the fibre is
removed from the stream by hand in a process known as stripping.
The jute fibre is 2.5 to 3 m long but ultimate fibre cell is 2.5 mm in length.
FIBRE-MATRIX INTERPHASE.
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Thermoplastic Composites
The interphase between the fibre & matrix can be easily identified, it is the
behaviour & prop of interphase that generally control the prop of the composite. The prop.
Of composite cannot achieved by any of the components acting alone.
Localised stress are generally highest near the interphase which may be
locus of premature feature of composite. The interphase must have appropriate character
in order to provide necessary load transfer from matrix to reinforcements.
Hence their should be strong adhesion forces between matrix & fibre
through interphase. This can also be achieved by coupling agents.
Coupling agents are define as materials that improves the adhesion bonds of
dissimilar surfaces. Coupling agents modify the interphase region to strengthen the
organic & inorganic boundary layers by
A much positive attempt to increase the adhesion between polymer & fibre
was link them by covalent bond using coupling agents.
Ex – Titonates, Silanes.
Coupling agents
Silanes :-
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Thermoplastic Composites
In general, the best coupling agents are those where the organizational
group on silicon has max. reactivity with the particular thermoplastic resin.
Chemistry of Silanes :-
“YRSiXg” where,
R = small aliphatic linkage -(CH,), that serves to attach the functional organic group to
silicon (Si).
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Thermoplastic Composites
Under ideal conditions a treated filler wets out & disperses readily in the
plastic with minimum viscosity. The treatment protects the filler against abrasion &
cleavage during mixing & in the final composite.
Titonates :-
Chemistry of Titonates :-
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Thermoplastic Composites
a. Unidirectional orientation.
b. Bidirectional Orientation.
In this type fibres are arranged in two directions usually normal to each
other for a lamina containing bidirectional orientation the strength & modulus can be
varied by employing different amount as well as different types of fibre in longitudinal &
transverse direction. For a balanced lamina, these properties are the same in both
directions.
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Thermoplastic Composites
Composition
SHORT FIBRE
LONG FIBRE
FABRIC
LAMINATED
PROCESSING.
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Thermoplastic Composites
Two techniques are generally used in manufacturing of thermoplastic composite they are
Open moulding
Close moulding
1. Use only one male or female die. 1. Use both male & female die.
side only.
are used.
Two process technique are given for the processing of thermoplastics materials are as
follows.
The glass fibre are impregnated & coated with thermoplastic resin & finally
chopped into pellets containing 20 to 30% wt fibre glass. The fibre glass in the pellets can
be obtained in 1/8 length to 3/8 in length.
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Thermoplastic Composites
1. MOULD CLOSED.
3. PLASTICISATION – in which the screw starts its backward rotation will material is
conveyed in forward direction & plasticization of pellets takes place due to shear heat &
band heaters.
4. INJECTION - After plasticization screw stops it backward motion & acts as plunger &
force material in forward direction in mold.
Precautions –
1. Due to hard nature of a fibres the modification in injection molding machine should be
done to avoid the damage of machine parts. Generally hard carbon steel or nitriding screw
& barrel are used.
Advantages –
Disadvantage –
ROTATIONAL MOULDING
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Thermoplastic Composites
STEPS IN ROTOMOULDING
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Thermoplastic Composites
2. MOLDING OR CURING -
The plastic material in mould is cured by the heat. Which is transfer from heating chamber
by conduction. While the mold is rotating biaxially in heating chamber.
3. COOLING -
4.EJECTION -
Advantages –
Disadvantages
This table Illustrates the increase in properties of thermoplastic materials when fiber
glass is added.
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Thermoplastic Composites
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Thermoplastic Composites
Typical properties of Reinforcing fibres and some materials with which they compete
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Thermoplastic Composites
APPLICATIONS.
1. THERMOPLASTIC COMPOSITE ROOF LIGHT, DOMES & SHEET.
2. STORAGE TANKS.
Storage tanks are used for house hold, factory & offices. These are light wt.
Leak proof, corrosion resistance oxygenic & strong & durable. These are easy to clean &
install.
3. SANITARY WARE
This are used in bath tub wash basin, shower & shower stalls are widely
use now a days. These have great advantage over ceramics like light in wt., unbreakable,
having minimum joints, easy to clean & mainly available in many attractive colours.
This are used in window pannel doors. They provide excellent water
roofing. They are light in wt.strong & available in many colour. ( pultrusion or continuous
laminating technique ).
6. FLOORING
The chairs & benches are used for outdoor uses. This can also be made fire retardants.
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Thermoplastic Composites
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Thermoplastic Composites
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Thermoplastic Composites
CONCLUSION
The tensile strength of thermoplastic can be at least double by the addition
of glass reinforcement. Unlike thermosetting reinforced plastic, fiberglass reinforce
thermoplastic compound & can be pelleted & used in conventional molding equipments.
Reinforced thermoplastic produce increase in strength & rigidity & marked decrease in co-
efficient of thermal expansion. The most significant effect in thermoplastic is retention of
izod impact strength at very low temp. Deflection temp is improved most markedly in
nylon. Other beneficial effects may include increase in hardness & abrasion resistance &
decrease in mold shrinkage, creep & dimensional change with humidity.
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Thermoplastic Composites
BIBLIOGRAPHY
1) J.A.Brydson, Plastic materials,Butterworth Heinemann Ltd. Oxford, Sixth Edition
(1996) Pg. 201-234, 240-258, 469, 574-577.
4) J.P. Agrawal, Mc Graw Hills, Delhi, Fifth Edition (1998) Pg. 6-85.
5) IPI Journal, Indian Plastic Institute, Mumbai, Volume 4-issue no.3.july/August (1999)
Pg. 1-6.
7) www.google.com
8) www.searchengine.com
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