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CMT Unit 2

The document discusses various types of polymer matrix composites, including thermosetting and thermoplastic resins as well as different reinforcement fibers like glass, carbon, and aramid. It also outlines several manufacturing processes for polymer matrix composites like hand lay-up, spray up, resin transfer molding, pultrusion, compression molding, filament winding, and injection molding. Each process shapes composites in different ways by combining fibers and resins.

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Roshan Sah
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57 views

CMT Unit 2

The document discusses various types of polymer matrix composites, including thermosetting and thermoplastic resins as well as different reinforcement fibers like glass, carbon, and aramid. It also outlines several manufacturing processes for polymer matrix composites like hand lay-up, spray up, resin transfer molding, pultrusion, compression molding, filament winding, and injection molding. Each process shapes composites in different ways by combining fibers and resins.

Uploaded by

Roshan Sah
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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COMPOSITES MATERIALS TECHNOLOGY

POLYMER MATRIX COMPOSITES


Unit 2 : POLYMER MATRIX COMPOSITES
Polymer matrix resins – Thermosetting resins, thermoplastic resins
Reinforcement fibres – Rovings – Woven fabrics – Non woven random mats
– various types of fibres.
PMC processes
– Hand lay-up processes
– Spray up processes
– Compression moulding
– Reinforced reaction injection moulding
– Resin transfer moulding
– Pultrusion
– Filament winding
– Injection moulding.
Fibre reinforced plastics (FRP), Glass fibre reinforced plastics (GFRP).
Polymer Matrix
• A polymer is defined as a long-
chain molecule containing one or
more repeating units of atoms
joined together by strong covalent
bonds. A polymeric material is a
collection of a large number of
polymer molecules of similar
chemical structure but not
necessarily of equal length.
Classification of Polymers
THERMOSET Polymers
Thermosets are materials which remain in a permanent solid state after being
cured one time. Polymers within the material cross-link during the curing process
to perform an unbreakable, irreversible bond.
1 Polyester Resins 3 Vinyl Ester Resins
2 Epoxy Resins 4 Phenolic Resins
5 Polyimide Resins

THERMOPLASTIC Polymers
A thermoplastic is any plastic material which melts into a soft, pliable form above a
certain temperature and solidifies upon cooling. Thermoplastics can be re-melted and
re-shaped any number of times. They are usually stored in the form of pellets prior to the
molding process.
1 Aliphatic Polyamides 3 Polyethylene Terephthalate
2 Polypropylene 4 Polyether Ether Ketone

5. Thermoplastic Polyimides
Elastomers (Rubbers)
The elastomers are the materials that can recover their
original dimensions after substantial extension or
compression. Such rubbery behavior is due to the presence
of tangled long chains and flexible polymers molecules.
When such a material is stretched, the individual long chains
are partially uncoiled but will retract or coil up again when
the force is removed.

Elastomers can be classified into thermosetting and thermo-


plastic elastomers. Most of the commonly used elastomers
are having long chains, which are chemically cross-linked
during the curing process.

Examples: Natural Rubber. Styrene–Butadiene Rubber,


Polybutadiene Rubber, Synthetic Polyisoprene Rubber,
Ethylene–Propylene (Diene) Rubber.
FIBRES
Fibre rovings: Woven Fabrics:

Non-woven fabric:
FIBRES
Natural Fibers: Synthetic Fibers:

Organic Fibers: Ceramic Fibers:


PROCESSING OF POLYMER MATRIX COMPOSITES
Polymer matrix composites (PMCs) have become one of the
important structural engineering materials. This is not only
because of the development of high-performance fibers such
as carbon, polyethylene, and aramid but also because of
some new and improved polymer matrix materials. The
mechanical properties of polymers in general are inadequate
for many engineering applications.

There is a variety of processing methods available to


produce PMC parts. Depending on the quality, property,
quantity, and cost of the product, a suitable processing
method can be selected.
Hand Lay-Up Process
Hand lay-up (contact molding) is a simple and cost-effective
process. This process is often used to build large structures
in small quantities. Reinforcements in the form of chopped
strand mat and woven rovings are generally used. The
quality of the product depends on the skill of the worker.
Molds for hand lay-up process are made out of
plaster of Paris, wood, FRP, or metals. The thickness of the
mold should be such that it should not deform excessively
during lay-up and release of the product.
A release film or layer should be placed over the
mold surface for the easy release of product from the mold.
Gel coat is a thin layer of resin (∼0.5 mm
thickness) applied over the release film. Gel coat gives
superior finish to the product. https://www.youtube.com/watch?v=y7oLzA5vTLg
Fiber layers wetted with resin are laid-up to the https://www.youtube.com/watch?v=EhAvCqtIo7w
required thickness and the stacking is called laminate. The
laminate provides strength and rigidity to the product. https://www.youtube.com/watch?v=sFYXHMZFqsU
https://www.youtube.com/watch?v=6C5u5B82kkY
SPRAY UP Process
Spray-up is a more cost-effective process than hand lay-up,
but the mechanical properties are much lower due to the
presence of randomly oriented chopped fibers. In this
process, continuous glass fiber roving is fed into a special
gun that chops the fibers into short lengths and mixes them
with resin, which is sprayed onto the mold. This process is
similar to hand lay-up process in almost all aspects, but it is
a slightly faster process.
The major advantages are low-cost tooling, simple
processing, possibility of on-site fabrication (the spray
equipment is portable), and virtually unlimited part size. An
additional advantage of spray-up is that it is amenable to
automation, thereby reducing labor costs and the risk of
exposure of workers to potentially hazardous styrene vapor
present in polyester resin.

https://www.youtube.com/watch?v=naSma_QeuDA

https://www.youtube.com/watch?v=Tk0Bn4XwdWA
https://www.youtube.com/watch?v=DG3dGZvzeaM
Resin Transfer Molding
RTM is a closed mold semi-mechanized
manufacturing method, generally used to produce
fiber-reinforced thermoset polymer products.
Unlike hand lay-up and spray-up processes, RTM
process gives better control on product thickness
and good surface finish on both sides. In this
process, the fiber is packed to the required
geometrical arrangement in the cavity of a closed
mold, and a liquid resin of low viscosity is injected
under pressure into the cavity. The resin wets the
fiber completely and then cures. The RTM process
gives faster production cycles than hand lay-up
process, since fast curing polyester or epoxy resins
https://www.youtube.com/watch?v=NzpHCjL_AnE
are generally used.
https://www.youtube.com/watch?v=NFi9g2-eTK8
Pultrusion
The Pultrusion process involves pulling continuous rovings
and/or mats through a resin bath and heated dies. This
process is useful to produce long products with constant
cross section, such as rods, tubes, and angles. This technique
is used for the manufacture of continuous composite
structural profiles. It is similar to aluminum or
thermoplastic extrusion; the main difference being that the
product is pulled from the die, whereas it is pushed through
the die in the extrusion process.

https://www.youtube.com/watch?v=4MoHNZB5b_Y
https://www.youtube.com/watch?v=D2ZMejajgtA
https://www.youtube.com/watch?v=LKe8g9oyhl0
Compression Moulding
Compression molding is one of the fastest polymer
composite processing methods. It is a closed mold
processing method, in which the product is made within the
cavity of a die. A predetermined quantity of molding charge
is placed in the die cavity. The molding charge can be bulk
molding compound (BMC), sheet molding compound (SMC),
prepreg, or wet lay-up. The die is closed and the required
pressure is applied by means of a press. The die remains
closed till the charge cures and becomes rigid enough to
maintain its shape. After the completion of curing, the
pressure is released and the die is opened to remove the https://www.youtube.com/watch?v=VscL0Uw7GRI
component.
https://www.youtube.com/watch?v=xz4LdsYjtDI
Filament Winding Process
Filament winding is a semiautomatic process for
manufacturing axisymmetric fiber-reinforced composite parts. Filament winding process can be used to
Continuous reinforcements in the form of rovings or yarns produce any product with positively
coated with matrix materials are wound using predesigned curved surface. Cylindrical, spherical,
machines, in which the fiber feeder traversing at speeds conical, and geodesic shapes are within
synchronized with the mandrel rotation controls the winding winding capabilities.
angles and the placement of the reinforcements.

https://www.youtube.com/watch?v=4ihtyjydzqA

https://www.youtube.com/watch?v=ign6W5ENJAA
Injection Molding
Injection molding is a very common processing method used
to form different-shaped products with thermoplastics
Structural Reaction Injection Molding (SRIM) Process: The
SRIM process is similar to the RTM process, with the
difference being in the resin used and the method of mixing
resins before injection.

https://www.youtube.com/watch?v=b1U9W4iNDiQ
https://www.youtube.com/watch?v=QeaZzjf4DBM&feature=emb_logo

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