Composites

Composites
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What are Composite Materials?

Composite Materials are those materials which are produced by combining two inherently different materials and have properties that exceed the constituent materials.
Advantages of Composites
High strength-to-weight ratio Directional strength Corrosion resistance Weather resistance Dimensional stability Non-magnetic Light weight High impact strength High dielectric strength (insulator) Low maintenance Long term durability
Composition of Composites
a) RESIN b) REINFORCEMENTS c) FILLERS d) ADDITIVES
Important considerations for the design of composite products include:

Type of fibre reinforcement (provides mechanical strength) Percentage of fibre or fibre volume Orientation of fibre (0o, 90o, +/- 45 oor a combination of these) Type of resin (it acts like glue that holds the composite together) Cost of product Volume of production (to help determine the best manufacturing method) Manufacturing process
Resins
a) The primary functions of the resin are to
transfer stress between the reinforcing fibres, b) act as a glue to hold the fibres together, c) protect the fibres from mechanical and environmental damage. Resins are divided into two major groups 1) Thermoset 2) Thermoplastic.
Thermoplastic resins
Become soft when heated, and may be shaped or molded while in a heated semi-fluid state and become rigid when cooled. Two types of thermoplastics are generally found: a) Commodity Thermoplastics (Low temperature application) Polyethylene, Polypropylene, PVC, Polystyrene b) Engineering Thermoplastics (High temperature application) Polyetheretherketone (PEEK), Polyphenylene Sulphide (PPS), Polyetherimide (PEI)
Thermoset resins
Are usually liquids or low melting point solids in their initial form. When used to produce finished goods, these thermosetting resins are cured by the use of a catalyst, heat or a combination of the two. Once cured, solid thermoset resins cannot be converted back to their original liquid form. Thermosetting resins - Unsaturated Polyesters, Epoxies, Vinyl esters and Phenolics.
Reinforcements
The primary function of fibres or reinforcements is to carry load along the length of the fibre to provide strength and stiffness in one direction. Types of Fibres Used for Reinforcements :a) Natural Fibres b) Synthetic Fibres
Major natural fibres of vegetative origin used as reinforcement

Fibre Bamboo Banana Coconut Flax Hemp Jute Kenaf Sisal Type Grass Stem Fruit Bast Bast Bast Bast Leaf
Advantages of natural fibre reinforced composites:

Reduction in density of products. Acceptable specific strength, toughness and stiffness in comparison with glass fibre reinforced composites. Ease of shaping into complex shapes in a single manufacturing process. Lower energy consumption from fibre growing to finished composites The manufacturing processes are relatively safe when compared with glass based reinforced composites. Possibility of recycling the cuttings and wastage produced during manufacturing and moulding. The production of natural fibres can be started with a low capital investment and with a lower cost. Bast fibres exhibit good thermal and acoustic insulation properties.
Disadvantages of natural fibre reinforced composites:

Lack of consistency of fibre quality, high level of variability in fibre properties depending upon source and cultivars. Preparation of fibre is labour intensive and time consuming. Poor compatibility between fibres and matrix, which requires surface treatment of fibres. High moisture absorption, which brings about dimensional changes in composite materials. Low density of bast fibres can be disadvantageous during composites processing application because fibre tends to migrate to the surface rather then getting mixed with matrix. Fluctuation in price depending upon the global demand and production. Problem of storing raw material for extended time due to possibility of degradation, biological attack of fungi and mildew, loss in colour, and foul odour development. Lower resistance to ultra violet radiation, which causes the structural degradation of the composites.
Synthetic Fibres
Carbon fibre Glass Aramid fibre
Glass
E-glass: S- glass: Alumina-calcium-borosilicate glass (electrical applications) Magnesuim aluminosilicate glass (reinforcements)
Glass offers good electrical, mechanical and thermal properties at a relatively low cost. E-glass S-2 glass
Density 2.56 g/cc 2.46 g/cc Tensile Strength390 ksi 620 ksi Tensile Modulus10.5 msi 13 msi Elongation 4.8% 5.3%
Aramid
Kevlar & Twaron Para aramid fibre are characterized by high tensile strength and modulus Very Good Impact Resistance Good Temperature Resistance Tensile Strength400 ksi Tensile Modulus18 Msi Density 1.44 g/cc Elongation 2.5%
Carbon Fibre
PAN: fibre made from Polyacrylonitrile precursor fibre High strength and stiffness Large variety of fibre types available Standard Modulus Density 1.79 g/cc Tensile Strength600 ksi Tensile Modulus33 Msi Elongation 1.8 % Intermediate Modulus 1.79 g/cc 800 ksi 42 Msi 1.8 %
Weight Considerations
Lightest
Aramid Fibre Carbon Fibre Glass Fibre
1.3-1.4 g/cc 1.79 g/cc 2.4 g/cc

Heaviest
Strength Considerations
Strongest
Carbon Fibre Glass Fibre Aramid Fibre
600-800 ksi 400-600 ksi 400 ksi

Weakest
Impact Resistance
Toughest
Kevlar Fibre Glass Fibre Carbon Fibre
Stiffness Considerations
Stiffest
Carbon Fibre Aramid Fibre Glass Fibre
30-40 msi 14 msi 10-13 msi
Cost Considerations
Cost Effective
Glass Fibre Aramid Fibre Carbon Fibre
$5.00-8.00/lb. $20.00/lb $30.00-$50.00/lb
Fabric Structures
Woven: Series of Interlaced yarns at 90 to each other Series of Interlooped Yarns Series of Intertwined, Spiral Yarns Oriented fibres either mechanically, chemically, or thermally bonded
Knit: Braided: Nonwoven:
Woven Fabrics
Basic woven fabrics consists of two systems of yarns interlaced at right angles to create a single layer with isotropic or biaxial properties.
Physical Properties
Construction (ends & picks) Weight Thickness Weave Type
Components of a Woven Fabric
Basic Weave Types

Plain Weave
Offers : 1. Dimensionally stable 2. Fabric Integrity

Basic Weave Types

Satin 5HS
Offers: 1. Smoother face 2. Improved translation of fibre properties

Basic Weave Types

2 x 2 Twill
Offers: Excellent drape ability, conformability

Basic Weave Types

Non-Crimp
Offers: Minimum crimp in yarns. Dimensionally stable.
Braiding
A braid consists of two sets of yarns, which are helically intertwined. The resulting structure is oriented to the longitudinal axis of the braid. This structure is imparted with a high level of conformability, relative low cost and ease of manufacture.
Braid Structure
Types of Braids
Triaxial Fabrics
A system of longitudinal yarns can be introduced which are held in place by the braiding yarns These yarns will add dimensional stability, improve tensile properties, stiffness and compressive strength. Yarns can also be added to the core of the braid to form a solid braid.
Fillers
Use of inorganic fillers in composites is increasing. Fillers not only reduce the cost of composites, but also frequently impart performance improvements that might not otherwise be achieved by the reinforcement and resin ingredients alone. There are a number of inorganic filler materials that can be used with composites including: Calcium carbonate Kaolin (hydrous aluminum silicate) Alumina trihydrate Calcium sulfate
Advantages of Using Fillers in Composites

Fillers reduce the shrinkage of the composites part. Fillers influences the fire resistance of laminates. Fillers lower compound cost by diluting more expensive resin and may reduce the amount of reinforcement required. Fillers can influence the mechanical strengths of composites. Fillers serve to transfer stresses between the primary structural components of the laminate (i.e., resin and reinforcement), thereby improving mechanical and physical performance.
Additives and Modifiers

A wide variety of additives are used in composites to modify materials properties and tailor the laminates performance. Although these materials are generally used in relatively low quantity by weight compared to resins, reinforcements and fillers, they perform critical functions. Fire resistance Viscosity control Electrical conductivity Toughness Antioxidants Antistatic agents Foaming agents
Process steps for fabrication of jute composite from thermoset resin:

Impregnation & drying- Jute substrate (nonwoven / woven fabric) is dipped in resin solution and squeezed to retain the required amount of resin and then passed through dryer to reduce the moisture. Cutting of substrate- The treated substrate is cut to size as per dimension required. Compression moulding- The cut material is placed inside the platen and are pressed to desired specific pressure and temperature for pre defined time to get moulded product. After completion of compression cycle, the platens are cooled to optimum temperature & then the pressure is released to take out the products. Post curing- Compression moulded products are post cured in oven to get fully cured and free from any precondensate polymer. Cutting & finishing - The moulded product is trimmed and finished.
Compression Molding
Compression Molding process involves the following steps: A pre-weighed amount of a polymer mixed with additives and fillers (charge) is placed into the lower half of the mold.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 polymer charge and forcing it to fill the mold cavity.The mold, equipped with a heating system, provides curing (cross-linking) of the polymer (if thermoset is processed). The mold is opened and the part is removed from it by means of the ejector pin.
Process steps for melt blend of jute PP:

Chopping- Jute fibre was stapled unto 100 mm Granulating- Stapled jute fibres were further reduced in size unto 10 mm (max) by passing through rotary granulating m/c Mixing- Short jute fibres with matrix were mixed in Kinetic mixer m/c at 5500 rpm & 199 C to form dough Pressing- Hot dough of mixture was flattened by pressing with hydraulic press to release excess heat Reduction of size- Flattened dough sheet was cut into pieces by running through band saw Granulating- Small pieces were further reduced in size by running through granulator. Injection molding- Granules of jute-pp were injection moulded to test pieces. For downloading this document and more please log on to www.textiletutorial.yolasite.com
Injection Moulding
Injection Molding process involves the following steps:

Resin is fed to the machine through the hopper. Colorants are usually fed to the machine directly after the hopper. The resins enter the injection barrel by gravity though the feed throat. Upon entrance into the barrel, the resin is heated to the appropriate melting temperature. The resin is injected into the mold by a reciprocating screw or a ram injector. The reciprocating screw offers the advantage of being able to inject a smaller percentage of the total shot. The mold is the part of the machine that receives the plastic and shapes it appropriately. The mold is cooled constantly to a temperature that allows the resin to solidify and be cool to the touch. For downloading this document and more please log on to www.textiletutorial.yolasite.com
INJECTION MOULDING
INJECTION MOULDING
Application areas of jute reinforced polymer composites with technical advantages

Automobile industries door panels seat backs headliners, dash boards trunk liners

Building Component Door Window Wall partition Ceiling Floor

Transport Sector (railway coach & vehicle) Flooring Ceiling Seat & Backrest

Furniture Table Chair Kitchen cabinet etc.
Conclusions
Composite materials offer endless design options. Matrix, fibre and Preform selections are critical in the design process. Structures can be produced with specific properties to meet end use requirements.
The End

Composites

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Composites

For downloading this document and more please log on to www.textiletutorial.yolasite.com

What are Composite Materials?

For downloading this document and more please log on to www.textiletutorial.yolasite.com

For downloading this document and more please log on to www.textiletutorial.yolasite.com

Important considerations for the design of composite products include:

For downloading this document and more please log on to www.textiletutorial.yolasite.com

Major natural fibres of vegetative origin used as reinforcement

Advantages of natural fibre reinforced composites:

For downloading this document and more please log on to www.textiletutorial.yolasite.com

Disadvantages of natural fibre reinforced composites:

For downloading this document and more please log on to www.textiletutorial.yolasite.com

For downloading this document and more please log on to www.textiletutorial.yolasite.com

For downloading this document and more please log on to www.textiletutorial.yolasite.com

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Aramid Fibre Carbon Fibre Glass Fibre

1.3-1.4 g/cc 1.79 g/cc 2.4 g/cc

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Carbon Fibre Glass Fibre Aramid Fibre

600-800 ksi 400-600 ksi 400 ksi

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Kevlar Fibre Glass Fibre Carbon Fibre

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Carbon Fibre Aramid Fibre Glass Fibre

30-40 msi 14 msi 10-13 msi

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Glass Fibre Aramid Fibre Carbon Fibre

$5.00-8.00/lb. $20.00/lb $30.00-$50.00/lb

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Knit: Braided: Nonwoven:

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Components of a Woven Fabric

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Basic Weave Types

Offers : 1. Dimensionally stable 2. Fabric Integrity

Basic Weave Types

Offers: 1. Smoother face 2. Improved translation of fibre properties

Basic Weave Types

Offers: Excellent drape ability, conformability

Basic Weave Types

Offers: Minimum crimp in yarns. Dimensionally stable.

For downloading this document and more please log on to www.textiletutorial.yolasite.com

For downloading this document and more please log on to www.textiletutorial.yolasite.com

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Advantages of Using Fillers in Composites

Additives and Modifiers

Process steps for fabrication of jute composite from thermoset resin:

For downloading this document and more please log on to www.textiletutorial.yolasite.com

For downloading this document and more please log on to www.textiletutorial.yolasite.com

Process steps for melt blend of jute PP:

Application areas of jute reinforced polymer composites with technical advantages

Application areas of jute reinforced polymer composites with technical advantages

Application areas of jute reinforced polymer composites with technical advantages

For downloading this document and more please log on to www.textiletutorial.yolasite.com

Application areas of jute reinforced polymer composites with technical advantages

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