MFGT290 Plastics Composites Ceramics

7/25/2019 MFGT290 Plastics Composites Ceramics

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efinition of Plastics

ll Materials

GasesSi(ple

3i4i"sSoli"s

Metals Polymers

(polymeric molecules)Cera(ics

Ther(osets

Heat Setting

Ther(oplastics

Heat Forming

%lasto(ers


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Intro"ction) Pol*(eric (aterials can 5e either

6 Ther(oplastics, ther(osets, an" elasto(ers7

6 %ach section is presente" in appropriate &rops) Ther(oplastics' Heat For(in& (aterials 8Can reheat for( a&ain

6 Car5on 5on"s are Satrate" an" are sin&le 5on"s7

6 Co(e in a .ariet* of for(s

) Pellets, po/"er 81'100 (icrons:, fla;e, chip, c5e, "ice,

) Shippe" in pac;a&es of choice6


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Co((ercial Ther(oplastics) Olefins

6 Unsatrate", aliphatic h*"rocar5ons (a"e fro( eth*lene &as

6 %th*lene is pro"ce" 5* crac;in& hi&her h*"rocar5ons of natral &as orpetrole(

) 3P% co((erciali+e" in 199 in hi&h pressre process

)


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MaBor Plastic Materials199!

) 3P% D7! M (etric tons

) HP% #7 M (etric tons

) PC #71 M (etric tons

) PP !7! M (etric tons

) PS 27@ M (etric tons

) PU 17@ M (etric tons

) P%T 17D M (etric tons) Phenolic 17# M (etric tons

Total 2>7D M (etric tons8>2E of (ar;et:


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-ec*clin& of Plastics

) State an" Fe"eral 3e&islation

) P%T 5ottle rec*clin&) Co"es for plastics

6 1 P%T

6 2 HP%

6 in*lPC

6 ! 3P%

6 # PP

6 D PS6 @ Other


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) (orphos' Moleclar strctre is incapa5le of for(in& re&lar or"er8cr*stalli+in&: /ith (olecles or portions of (olecles re&larl* stac;e" in

cr*stal'li;e fashion7) ' (orphos 8/ith'ot shape:

) Usall* transparent 8Clear 5a&s:

) 3ess shrin;a&e /ith a(orphos (aterials7

States of Ther(oplastic Pol*(ers

(orphos Pol*(ers

)


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) Cr*stalline' Moleclar strctre for(s re&lar or"er 8cr*stals: /ith (olecles or portions of(olecles re&larl* stac;e" in cr*stal'li;e fashion7

) Most cr*stalline pol*(ers are se(i'cr*stalline 5ecase .er* fe/ plastics are 100Ecr*stalline7 ll ha.e 5oth re&ions that are cr*stalline an" so(e that are a(orphos

) Usall* Opa4e an" not transparent

) More (ol"in& shrin;a&e /ith6 cr*stalline (aterials7

States of Ther(oplastic Pol*(ers

Cr*stalline Materials

)3P% HP% PP

)P%T P


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Fnctional Grops

) Certain che(ical characteristics associate" /ith .arios &rops of

ato(s, calle" fnctional &rops7) Particlar &rops of ato(s occr in a lar&e (olecle, thecharacteristic che(istr* is anticipate"76 %=a(ple, PP has Fnctional &rops can 5e attache" to 5asic &rops of car5on

ato(s 5* replacin& on H ato(7

6ote$ PP is Mostl* Isotactic' CHon one si"e of pol*(er chain 8isolate":7Co((ercial PP is 90E to 9#E Isotactic an" not tactic 8ran"o(: or s*n"iotactic

C C

H CH

H H

n

C C

H CH

H H

n

C C

H CH

H H

n

C C

H CH

H H

n


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Fnctional Grops

) arios (olecles of car5on, h*"ro&en an" o=*&en illstratin& the

"ifferences properties /ith "ifferent ato(ic arran&e(ents) isoprop*l alcohol' r55in& alcohol) (eth*leth*l ether' anesthetic

) acetone' co((on sol.ent

) (eth*l acetate' s/eet che(ical perf(e

) propional"eh*"e' sharp s(ellin& che(ical) propanoic aci" relate" to .ine&ar

) ro(atic &rop' P


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Pol*(ers Units

) Jst as 2 car5ons ato(s are 5on"e" to&ether in ethane, three, for, or

(ore car5ons can 5e 5on"e" in chain'li;e arran&e(ent, so(eti(esthosan"s of ato(s lon&7

) 3on& chains of ato(s are pol*'(ers 8(an*'(ers or nits:

) Fi&re

6 Pol*eth*lene PP PS PC

6ote$ PP is Mostl* Isotactic' CHon one si"e of pol*(er chain 8isolate":7

Co((ercial PP is 90E to 9#E Isotactic an" not tactic 8ran"o(: or s*n"iotactic

C C

H H

H H

n

C C

H CH

H H

n

C C

H Cl

H H

n

C C

H

H H

n


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Co(ple= Pol*(ers) Pol*(er chains /ith ato(s other than car5on

6 Usall* pol*(er chains /ith C an" , O, S, F, an" Cl

) PC has Cl *lon has O an" Pol*rethane has O an"

) P%T has O an" 5en+ene rin& PC has O an" 5en+ene rin&

)


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For(ation of Pol*(ers

) ""ition 8or Chain'Gro/th: Pol*(eri+ation

6 Most Co((o"it* 8cheap: plastics

6 Instantaneosl*, the pol*(er chain for(s /ith no 5*'pro"cts

6 Chain'reaction (echanis( that procee"s 5* se.eral se4ential steps

as sho/n in Fi&re 27207 Pol*(eri+ation 5e&ins at one location on

the (ono(er 5* an initiator

) Con"ensation 8or Step'/ise: Pol*(eri+ation6 Most %n&ineerin& plastics 8pellets of *lon, PC, P%T, Pol*rethane:an"

the(osets 8li4i"s of epo=*, pol*ester, pol*rethane:

6 Step'&ro/th pol*(eri+ation procee"s 5* se.eral steps /hich reslt in 5*'

pro"cts7

6 Mono(ers co(5ine to for( 5loc;s 2 nits lon&

6 2 nit 5loc;s for( !, /hich intern for( > an" son on ntil the process is

ter(inate"7

6 -eslts in 5*'pro"cts 8CO2, H2O, cetic aci", HCl etc7:


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*lon 8or pol*a(i"e: an" PC) The repeatin& 'COH' 8a(i"e: lin;

) Pol*(eri+e" /ith con"ensation reaction6*lon D' Pol*caprolacta($ NH8CH2:#CO=

6*lon D,D' Pol*he=a(eth*lenea"ipa(i"e$

) NH8CH2:DHCO 8CH2:!CO=

6*lon 12' Pol*812'a(ino"o"ecanoic aci":' NH8CH2:11CO=

) Pol*car5onates are linear, a(orphos pol*esters 5ecase the*

contain esters of car5onic aci" an" an aro(atic 5isphenol 8CDH#OH:

) Pol*(eri+e" /ith con"ensation reaction

O C

CH2

CH2C

O

O

n


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Ho(opol*(ers) Plastics In.ol.in& Three S5stittions 8se Ta5le 72:

C C

A

Q R

n

C C

F F

F F

n

e7&7 PTF%pol*tetrafloroeth*lene

8Teflon:


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Copol*(ers an" Ter Pol*(ers) Plastics In.ol.in& T/o (ers in chain or (ers 8


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Ther(osets

) Ther(osets are pol*(ers that n"er&o a che(ical reaction

"rin& the pol*(eri+ation7

) Ther(osettin& reaction is not re.ersi5le n"er heat7

) %po=*

6 Stan"ar" epo=* is 5ase" on 5isphenol an" epichloroh*"rin7

6 Properties incl"e &oo" a"hesion to (an* s5strates, lo/shrin;a&e, hi&h electrical resisti.it*, &oo" corrosion resistance, an"

ther(al7

6 Processin& is achie.e" /ithot &eneration of .olatiles7

P l t " P l th


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Pol*ester an" Pol*rethane) Pol*ester

6 Ther(oset reaction 5et/een a "ifnctional aci" 8or anh*"ri"e: an" a "ifnctional alcohol 8&l*col:

6 Heat or ra"iation can tri&&er the cross lin;in& reaction

6 ccelerators 8or pro(oters: spee" p the reaction7

6 Con"ensation -eaction reslts in CO2an" H2O76 Mono(er re4ire" to pol*(eri+e, e7&7, St*rene at 0E to #0E in co((ercial pol*ester s*ste(s

) Polrethane6 -eaction 5et/een isoc*anate an" alcohol 8pol*ol:7 Con"ensation -eaction reslts in CO 2an"

H2O7

6 Crosslin;in& occrs 5et/een isoc*anate &rops 8'CO: an" the pol*ol?s h*"ro=*l en"'&rops 8'OH:

6 Ther(oplastic PU 8TPU: ha.e so(e crosslin;in&, 5t prel* 5* ph*sical (eans7 These 5on"scan 5e 5ro;en re.ersi5l* 5* raisin& the (aterial?s te(peratre, as in (ol"in& or e=trsion7


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Ther(oplastic %lasto(ers, atral -55er

) Ther(oplastic %lasto(ers reslt fro( copol*(eri+ation of t/o or

(ore (ono(ers76 One (ono(er is se" to pro.i"e the har", cr*stalline featres, /hereas the other(ono(er pro"ces the soft, a(orphos featres7

6 Co(5ine" these for( a ther(oplastic (aterial that e=hi5its properties si(ilar tothe har", .lcani+e" elasto(ers7

) Ther(oplastic Urethanes 8TPU: /ere the first Ther(oplastic%lasto(er 8TP%: se" for seals &as;ets, etc7

) Other TP%s6 Copol*ester for h*"ralic hoses, coplin&s, an" ca5le inslation7

6 St*rene copol*(ers are less e=pensi.e than TPU /ith lo/er stren&th

6 St*rene'5ta"iene 8S


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Plastics estions17 5on" 5et/een 2 car5on ato(s is a KKKKKKK 5on"7

27 CH &rops is calle" a KKKKKKKKKK &rop7

7 "ash 5et/een ato(s in"icates a KKKKKK 5on"7

!7 The s(all repeatin& nits that (a;e p a plastic (olecle are calle" KKKKKKKKKKK

#7 Ahat "oes pol* (ean KKKKKKKKKKK

D7 t*pes of inter(oleclar forces fon" in plastics are KKKKKKKKKKK , KKKKKKKKKKKK, an"KKKKKKKKKKKK7

@7 Ahat t*pe of 5on"in& (a;es *lon D stron&er than n*lon 12 KKKKKKKKKKKKK

>7 Cr*stalline plastics are (ore ri&i" an" not as transparent as KKKKKKKKK plastics7

97 KKKKKKK (aterial (a* 5e softene" repeate"l* /hen heate" an" har"ene" /hen coole"7

107 The ter( se" to "escri5e t*in& to&ether a"Bacent pol*(er chains is KKKKKKK

117 If the "ifferent (ers (a;e p the co(position of a pol*(er , it is calle" a KKKKKK7

127 H*"ro&en (olecle /hich contains so(e "o5le 5on"s is calle" KKKKKKKK7

17 Is PC a copol*(er KKKKKKKKK %=plain' KKKKKKKKKKKKKKKKKKKKKKKKKKKKK7

1!7 Ahat is the &eneral strctre of an alternatin& copol*(er KKKKKKKKKKKKKKKKKK71#7 If a car5on chain has a (eth*l si"e &rop, is it 5ranche" KKKKKKKKK %=plain'

KKKKKKKKKKKKKKKKKKKKKKKKKKKKK7

1D7 If a (aterial is transparent, is it cr*stalline KKKKKKKKKKKK

1@7 Ahat effect "o "ipoles an" h*"ro&en 5on"s ha.e on (eltin& point of pol*(ers KKKKKKKKKKK

1>7 Is resi"al stress s*non*(os /ith orientation KKKKKKKKKKKKKKKKKKKK

197 Ho/ "oes the tensile stren&th an" (eltin& point chan&e /ith increasin& cr*stalli+ation KKKKKK


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Processin& of Pol*(ers) Ther(oplastics

6inBection (ol"in&, e=trsion, 5lo/ (ol"in&, ther(ofor(in&,rotational (ol"in&, co(pression (ol"in&

6 Usall* ses hi&h pressre processes an" i(parts hi&h resi"al

stresses on the (aterial /hich an case /arpin& in part7

) Ther(osets6 co(pression (ol"in&, reaction inBection (ol"in&, resin transfer

(ol"in&, castin&, han" la*p, etc7

) %lasto(ers

6 co(pression (ol"in&, e=trsion, inBection (ol"in&, castin&7


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InBection Mol"in& Process an" C*cle Ti(e


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%=tr"er %4ip(ent) %=it +one' "ie

6 "ie i(parts shape on the (aterial, e7&7, ro", t5e, sheet, channel

6 e=it (aterial is calle" extrudate6 e=tr"ate s/ells at en" of "ie "e to nor(al forces fro( the pol*(er flo/, calle" die swell

) Cooling zone

6 /ater 5ath or air coole" to lo/er the te(peratre 5elo/ T&

) =iliar* e4ip(ent6 pller

6 rollers for proper thic;ness

6 Ain"'p or ct off

ie S/ell


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Co(pression Mol"in& Process)Materials

)Ther(osets$ Pol*ester, in*l ester, or %po=* resins /ith &lass fi5er)Sheet Mol"in& Co(pon" 8SMC:,


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-esin Transfer Mol"in& Process-ef$ MSU Ttorial' http$islnotes7cps7(s7e"trpli4i"rt(

)Materials)Ther(osets$ Pol*ester, in*l ester, or %po=* resins /ith &lass fi5er


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Pol*rethane Processin&

) Pol*rethane can 5e processe" 5*

6 Castin&, paintin&, foa(in&

6 -eaction InBection Mol"in& 8-IM:

h i l


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Ther(oset -eactin& Pol*(ers) Process Ain"o/

6 Te(peratre an" pressre (st 5e set to pro"ce che(ical reaction

/ithot e=cess flash 8too lo/ a .iscosit*:, short shot 8too hi&h a

.iscosit*:, "e&ra"ation 8too (ch heat:

C i l"i


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Co(pression Mol"in&) Co(pression (ol"in& /as specificall* "e.elope" for replace(ent of (etal

co(ponents /ith co(posite parts7 The (ol"in& process can 5e carrie" ot /ith

either ther(osets or ther(oplastics7 Ho/e.er, (ost applications to"a* sether(oset pol*(ers7 In fact,co(pression (ol"in& is the (ost co((on (etho"

of processin& ther(osets7

- i T f M l"i


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-esin Transfer Mol"in&

) In the -TM process, "r* 8i7e7,ni(pre&nate" :

reinforce(ent is pre'shape" an" oriente" into s;eleton ofthe actal part ;no/n as the prefor( /hich is inserte" into

a (atche" "ie (ol"7

)The heate" (ol" is close" an" the li4i" resin is inBecte"

) The part is cre" in (ol"7

) The (ol" is opene" an" part is re(o.e" fro( (ol"7

I B i M l"i Gl - i f " C i


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InBection Mol"in& Glass -einforce" Co(posites

) Plastic pellets /ith &lass fi5ers are (elte" in scre/,

inBecte" into a col" (ol", an" then eBecte"7

Glass fille" resin pellets

Ch 1! C i


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Chap 1!$ Co(posites) Co(posite Materials

) Co(posite Constrction) Co(posite pplications

) Processin& of Co(posites

) -e.ie/ estions

P l C i


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Pol*(ers Co(posites

) O5Becti.es6 efine the co(ponents an" "ifference t*pes of co(posites7

6 %=plain the "ifferent t*pes of co(posite constrction an" the reasons 5ehin"

the(7

6 escri5e the .arios (anfactrin& (etho"s se" to pro"ce co(posites76 3ist the "ifferent reinforcin& (aterials se" in co(posites7

6 3ist the .arios (atri= (aterials se" in co(posites7

) %=cellent Ae5 sites

6 Michi&an State http://islnotes.cps.msu.edu/trp/

6 U of ela/are http://www.ccm.udel.edu/publications/CU/99/

6 Cornell Uni.ersit* http://www.engr.siu.edu/staff/abrate/!"#$%&/lin's.htm

C it


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Co(posites) Co(posite "efinition

6 co(posite is a (aterial co(prise" of t/o or (ore ph*sicall* "istinct

(aterials /ith at least one (aterial pro.i"in& reinforcin& properties onstren&th an" (o"ls7

) atral Co(posites6


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Co(posite Classifications

) -einforce(ent T*pe

6 iscontinos 8fi5ers are choppe" an" "isperse" in (atri= resin:) Short fi5ers$ fi5er len&ths (( or less 8(ost inBection (ol"e" (aterials:

) 3on& fi5ers$ fi5er len&ths &reater than D ((7 8So(e inBection (ol"e" (aterials /ith D(( fi5ers,Sheet Mol"in& Co(pon" 8SMC: /ith 1 fi5ers, FP irecte" Fi5er Prefor(s for -TM an" S-IM:

) Particlates$ fi5ers is for(s as spheres, plates, ellipsoi"s 8so(e inBection (ol"e" (aterialsreinforce" /ith (ineral fi5ers:

6 Continos 8fi5ers are thro&hot strctre /ith no 5rea; points:

) Glass ro.in&$ &lass 5n"les are /on" p in a pac;et si(ilar to *arn7

) -o.in& is /o.en into se.eral /ea.es sin& a loo( (achine li;e in apparel7

6 Mat pro"cts$ ran"o( s/irl &lass pattern7

6 Ao.en pro"ct$ ro.in& is /o.en into (achine "irection 8/arp: an" cross "irection 8/eft:

6 Uni pro"ct$ ro.in& is /o.en in one "irection /ith a cross threa" &i.en to hol" (atto&ether7

Gl Fi5 li ti


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Glass Fi5er pplications) iscontinos 8Choppe": Fi5er

) Short fi5er 83 ((: reinforce(ent for ther(oplastic (aterials that are

inBection (ol"e" 8PP an" *lon:) 3on& Fi5er 83D((: reinforce(ent for ther(oplastic (aterials that are

inBection (ol"e" 8*lon:

) Choppe" Fi5er 8312 (( to 2# ((: reinforce(ent for ther(oset 8SMC

an"


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Car5onGraphite Fi5ers

) ee" for reinforce(ent fi5ers /ith stren&th an" (o"liihi&her than those of &lass fi5ers has le" to "e.elop(ent ofcar5on

) Tho(as %"ison se" car5on fi5ers as a fila(ent forelectric li&ht 5l5

) Hi&h (o"ls car5on fi5ers first se" in the 19#0s) Car5on an" &raphite are 5ase" on la*ere" strctres of

he=a&onal rin&s of car5on

) Graphite fi5ers are car5on fi5ers that

6 Ha.e 5een heat treate" to a5o.e 000F that cases "i(ensionalor"erin& of the ato(s an"

6 Ha.e car5on contents G-%T%- than 99E

6 Ha.e tensile (o"ls of !! Gpa 8#0Mpsi:



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) ee" for reinforce(ent fi5ers /ith stren&th an" (o"liihi&her than those of &lass fi5ers has le" to "e.elop(ent ofcar5on

) Tho(as %"ison se" car5on fi5ers as a fila(ent for electricli&ht 5l5

) Hi&h (o"ls car5on fi5ers first se" in the 19#0s) Car5on an" &raphite are 5ase" on la*ere" strctres of

he=a&onal rin&s of car5on

) Graphite fi5ers are car5on fi5ers that

6 Ha.e 5een heat treate" to a5o.e 000F that cases "i(ensionalor"erin& of the ato(s an"

6 Ha.e car5on contents G-%T%- than 99E

6 Ha.e tensile (o"ls of !! GPa 8#0Mpsi:



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) Manfactrin& Process

6 Crrent preferre" (etho"s of pro"cin& car5on fi5ers are fro(

pol*acr*lonitrile 8P:, ra*on 8re&enerate" celllose:, an" pitch7

) P

6 Ha.e &oo" properties /ith a lo/ cost for the stan"ar" (o"ls

car5on6 Hi&h (o"ls car5on is hi&her in cost 5ecase hi&h te(peratres

re4ire"

) PITCH

6 3o/er in cost than P fi5ers 5t can not reach properties of P

6 So(e Pitch 5ase" fi5ers ha.e ltra hi&h (o"ls 8@2# GPa .erss

#0GPa: 5t lo/ stren&th an" hi&h cost 8Ta5le '2:



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) P Manfactrin& Process Fi&res ' an" '!

6 Pol*acr*lonitrile 8P: is co((erciall* a.aila5le te=tile fi5er an" is a rea"*

(a"e startin& (aterial for P'5ase" car5on fi5ers6 Sta5ili+e" 5* ther(osettin& 8crosslin;in&: so that the pol*(ers "o not (elt in

s5se4ent processin& steps7 P fi5ers are stretche" as /ell

6 Car5oni+e$ Fi5ers are p*rol*+e" ntil transfor(e" into all'car5on

) Heate" fi5ers 1>00F *iel"s P fi5ers at 9!E car5on an" DE nitro&en

) Heate" to 200F to re(o.e nitro&en *iel"s car5on at 997@E Car5on

6 Graphiti+e$ Carrie" ot at te(peratres &reater than 200 F to

) I(pro.e tensile (o"ls 5* i(pro.in& cr*stalline strctre an" three "i(ensional

natre of the strctre7

6Fi5ers are srface treate") Si+in& a&ent is applie"

) Finish is applie"

) Coplin& a&ent is applie"

6 Fi5ers are /on" p for ship(ent



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) PITCH Manfactrin& Process) Pitch (st 5e con.erte" into a sita5le fi5er fro( petrole( tar

) Pitch is con.erte" to a fi5er 5* &oin& thro&h a (eso'phase /here the pol*(erchains are so(e/hat oriente" tho&h is a li4i" state 8li4i" cr*stal phase:

) Orientation is responsi5le for the ease of consoli"ation of pitch into car5on

6 Sta5ili+e" 5* ther(osettin& 8crosslin;in&: so that the pol*(ers "o not (elt ins5se4ent processin& steps

6 Car5oni+e$ Fi5ers are p*rol*+e" ntil transfor(e" into all'car5on) Heate" fi5ers 1>00F

) Heate" to 200F

6 Graphiti+e$ Carrie" ot at te(peratres &reater than 200 F to

) I(pro.e tensile (o"ls 5* i(pro.in& cr*stalline strctre an" three "i(ensional

natre of the strctre76 Fi5ers are srface treate"

) Si+in& a&ent is applie"

) Finish is applie"

) Coplin& a&ent is applie"

6 Fi5ers are /on" p for ship(ent

Car5on Fi5er Mechanical Properties


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!2

Car5on Fi5er Mechanical Properties

) Ta5le '2 8fro( MFGT 10!:

Carbon Fiber Mechanical PropertiesPAN Based PITCH Based Rayon Based

Tensile Modulus (Mpsi) 33 !" #3 !! !$%

Tensile &tren'th (Msi) $* $3! $# $#! $+!

,lon'ation (-) +$ $" $% $ #!

.ensity ('/cc) +$* +$% +$% #$ +$"

Carbon Assay (-) %# + %0 %% %%

Co(posites Ha.e a Fi5er Prefor(


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!

Co(posites Ha.e a Fi5er Prefor(

) Fi5er t*pe

6 -o.in& for( that can 5e spra*e" into a ' prefor(6 -o.in& for( that is /o.en into a &lass sheet an" then for(e" to

shape 8prefor(:

Sheet Mol"in& Co(pon" 8SMC:


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Sheet Mol"in& Co(pon" 8SMC:

) SMC is the paste that is co(pression (ol"e"

6 E pol*ester resin an" str*rene, /hich pol*(eri+es an" crosslin;s6 E &lass fi5ers 81 fi5ers:

6 E Calci( Car5onate

Processin& of Co(posites


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Processin& of Co(posites) Open Mol" processes

6 ac( 5a&, pressre 5a&, SC-IMP

6 atocla.e$ ppl* ac( Pressre an" Heat in an o.en /hich can 5e # feet to 00 feet lon&

Strctral -IM


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Strctral -IM

) Fi5er prefor( is place" into (ol"7

) Pol*ol an" Isoc*anate li4i"s are inBecte" into a close"(ol" an" reacte" to for( a rethane7



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) Open Mol" processes

6 Han" la*'p an" Spra*'p

6 Fila(ent /in"in&

Co(posite Classifications


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Co(posite Classifications) -esin 8or (atri=: t*pe

6 Ther(oset resins' those that n"er&o a che(ical cross'lin;in& reaction

) %po=*Pol*esterPol*rethane Phenolic

) Silicone Mela(ine6 Ther(oplastic resins' those that are for(e" n"er heat

) Pol*a(ines 8n*lon: 8short an" lon& fi5ers:

) Pol*esters 8short an" lon& fi5ers:

) Pol*prop*lene 8short, lon& fi5ers an" continos fi5ers:

) Other ther(oplastic resins 8short an" lon& fi5ers:

) Fi5er -einforce(ents6 Glass for reinforce" co(posites /ith concentrations less than #0E /ei&ht

6 Car5on fi5er for ".ance" 8aerospace: co(posites /ith concentrations &reater than D0E 5* /ei&ht7

6 e.lar fi5er for ".ance" 8aerospace: co(posites7

) Core or 3a(inate strctres6 foa( core (aterial can 5e a""e" 8san"/iche": 5et/een the la*ers of resin an" fi5er7

6 Co(posite la(inate has a core (aterial /ith resin an" fi5er co(5inations

Processin& an" Co(posites estions


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!9

Processin& an" Co(posites estions

17 co(posite (aterial is a co(5ination of a reinforcin& ele(ent an" KKKKKKKKKKK7

27 Ho/ are a".ance" co(posites are "istin&ishe" fro( reinforce" plasticsKKKKKKKKK7 The fi5ers in a".ance" co(posites are sall* (a"e fro( /hat KKKKKKKKKKKK

!7 Ahat t/o fnctions "oes the (atri= of a co(posite ser.e KKKKKKKKKKKKKKKK

#7 Un"er /hat con"itions shol" &raphite fi5ers .erss car5on fi5ers 5e se" KKKKKKK

Chap 1#$ Cera(ics


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#0

Chap 1#$ Cera(ics) Cera(ic pplications

) Cera(ic Strctres) Glass

) ".ance" Cera(ics

)Processin& of Cera(ics

) -e.ie/ estions

Intro ct on


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#1

o c o

) Cera(ics are

6 co(ple= co(pon"s an" soltions that contain 5oth (etallic an"

non(etallic ele(ents,

6 heate" at least to incan"escence "rin& processin& applications,

6 t*picall* har" an" 5rittle,

6 e=hi5it hi&h stren&th an" hi&h (eltin& points,

6 e=hi5it lo/ ther(al an" electrical con"cti.it*7

) pplications

6 Potter*, 5ric;, tile, &lass, o.en/are, (a&nets, refractories 8resist hi&h

te(peratre:, cttin& tools76 Frnace linin&s an" tiles for space shttle "e to hi&h resistance to

heat7

6 Spercon"cti.it* applications

era( cs


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#2

) Tra"itional cera(ics are (a"e fro( clay, silica, and feldspar

) Strctral cla*s for 5ric;s, se/er pipes, "rain tiles, an" floor tilesare (a"e fro( natral cla*s (a"e fro( three 5asic co(ponents

) Tra"itional cera(ic pro"cts are china, "ental porcelain, an"sanitar*'/are

) Technical cera(ics are (ainl* pre co(pon"s or nearl* preco(pon"s of pri(aril* o=i"es, car5i"es, or nitri"es76 Car5i"es$ /ith Silicon, tn&sten, titani(, or tantal( Car5i"es

) %=tre(e har"ness an" /ear resistance allo/s Use for cttin& tools an" a5rasi.es

6itri"es$ /ith


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#

) Cera(ics co(es fro( Gree; /or" keramos, /hich (eans

potters clay7

) Cera(ics are "i.erse &rop of non(etallic, inor&anic soli"

co(pon"s /ith a /i"e .ariet* of co(positions an"

properties7

) Cera(ics are cr*stalline co(pon"s (a"e p of (etallic an"non(etallic co(pon"s /ith properties that "iffer fro( the

constitents7

)Cera(ics in the for( of potter* are a(on& the ol"estpro"cts (anfactre" 5* h(ans7

6 Cla* is ine=pensi.e (aterial an" is fon" thro&hot the /orl"7

6 %arl* cla* pro"cts /ere sn "rie" not fire"7

6 Firin& as se" in potter* "ates 5ac; to aron" 2000 to 000


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#!

p) Cera(ics are cr*stalline li;e steel 5t ha.e fe/ free electrons

at roo( te(peratre an" ths are lo/ con"cti.it*7

) Cera(ics stren&ths ha.e hi&her co(pressi.e than tensile7

) Cera(ics are totall* elastic, e=hi5itin& no plasticit* /henloa" is applie" /ith little or no "efor(ation prior to fractre7

) In &eneral cera(ics ha.e the hi&hest (eltin& points of an*(aterials7 -an&e fro( #00F to as hi&h as @000F7

) Manfactrin& of cera(ics in.ol.es65len"in& fine startin& (aterials /ith /ater to for( (ass that is shape"

6 for(ation incl"es e=trsion, pressin&, an" castin&,

6 se of potter?s /heel for cps, 5o/ls, sacers, etc7

6 e=tr"e" to (a;e 5ar shapes or pore" into (ol" asslipslrr*

6 after for(in& pro"ct is "rie" to re(o.e /ater an" fire" for stren&th

6 for(in& pro.i"es fsion 8sintering: an" che(ical reaction for 5on"in&

6 &la+in& /ith cera(ic coatin& for s(ooth srface

era( cs Mater a s) Properties


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##

) Properties

6 ar* "epen"in& on co(position, (icrostrctre, an" processin&7

6 %=cellent resistance to

) co(pressi.e loa"s, a5rasion, heat, an" stainin&

) che(ical attac;s, /eather attac;s, 5en"in& 8e=cellent ri&i"it*:

6 Poor resistance to tensile loa"s, spallin& 8ther(al crac;in& cera(ics:

6 Most cera(ics /ill crac; if ther(al c*cle", e=cept P*re= &lass /hich contains 5oric

o=i"e to pro.i"e e=pansion properties7

) pplications6 "ielectric (aterials for capacitors /ith "is; capacitors 8(ainl* 5ari( titanate:

5ein& the (ost co((on7

6 Se(icon"ctor applications /ith sintere" o=i"es, e7&7, ther(istors, /hich are

ther(all* sensiti.e resistors se" for te(peratre control

6 Pie+oelectric cera(ics 8


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#D

) Glasses are "escri5e" as sper'coole" li4i"s76 Glasses "o not 5eha.e li;e (etals 5t (ore li;e pol*(ers /hen

coole" fro( (olten con"ition

) Metals e=hi5it a "efinite 4antit* of heat &i.en off /hen coole" an" for( acr*staline 8or re&lar: strctre /hen coole"7

6 Heat is calle" heat of soli"ification

) Pol*(ers e=hi5it chan&es in .ol(e /hen coole" /hich (a* for( a cr*stallineor a(orphos strctre "epen"in& pon the natre of the pol*(er an" .erss

te(peratre that has an inflection point, ;no/ as &lass transition te(peratre7) Glass is a transparent silica pro"ct /hich (a* for( an a(orphos or

cr*stalline strctre "epen"in& pon heat treat(ent "rin& pro"ction7

) Glass "o not e=hi5it an* in"ication of transition or a clear point of inflection/hen coolin& fro( (olten state7

) Glass is consi"ere" a .iscos li4i" /hen coole" fro( (olten state7

) Glass has the appearance an" feel of a soli" (aterial 5t /ill flo/ li;e a li4i"&i.en ti(e, e7&7, thic;er &lass at 5otto( of /in"o/ pane7

6 Cr*stallinit* of &lasses is (easre" /ith ra*s an" 'ra* "iffraction7) More cr*stalline the &lass the (ore ra*s are "iffracte"

ass Man actr n&


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) Glass 5lo/in& process

6 Glass 5lo/pipe is a hollo/ iron t5e fro( ! to # ft lon& /ith a ;no5 at

one en" an" a (othpiece at the other en"76 ip ;no5 en" into (elte" &lass, /here &lass stic;s to the en" of pipe7

6 ir is 5lo/n &entl* /hile rotatin& pipe /hich pro"ces a hollo/ 5l5

of &lass, /here the thic;ness of the 5l5 "epen"s on si+e of 5l57

6 The 5l5 cools an" soli"ifies into a n(5er of s*((etrical shapes7

6 Mol"s are se" to rapi"l* cool &lass an" allo/ (ore (an* shapes,

incl"in&, 5ottles, "ishes, la(ps, an" Bars7

) Co(position6 Glass is (a"e pri(aril* of san" 8silicon "io=i"e:

6 Silica or 4art+ &lass is pre silicon "io=i"e 8.er* sta5le:

6 Ain"o/ &lass is (a"e of san" 8SiO2:, li(estone 8CaCO:, an" so"a ash

8a2Co:

MFGT290 Plastics Composites Ceramics

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