Polymer Matrix Composites (PMC) Manufacturing and application

40
Application & Manufacturing process of Polymer matrix ComPosites (PmC) By- 13.02.08.040 Mohammad Mehadi Hasan 13.02.08.059 Raju Ahmed 13.02.08.062 Yeadul Islam Sazal 13.01.08.021 Md. Sazzad Hossain Ahsanullah University of Science and Technology 1

Transcript of Polymer Matrix Composites (PMC) Manufacturing and application

Page 1: Polymer Matrix Composites (PMC) Manufacturing and application

Application & Manufacturing process of

Polymer matrix ComPosites (PmC)

By-

13.02.08.040 Mohammad Mehadi Hasan

13.02.08.059 Raju Ahmed

13.02.08.062 Yeadul Islam Sazal

13.01.08.021 Md. Sazzad Hossain

Ahsanullah University of Science and Technology

1

Page 2: Polymer Matrix Composites (PMC) Manufacturing and application

Composite Materials Classification of composites Polymer & Polymer matrix composite Classification of Polymers Fibers in PMCs Polymer Processing Applications Of PMCs Limitations of PMC

Contents:

2

Page 3: Polymer Matrix Composites (PMC) Manufacturing and application

Composite Materials

Made from two or more constituent materials

Materials having significantly different physical or chemical properties.

Produced material have different characteristics from the individual components.

3

Page 4: Polymer Matrix Composites (PMC) Manufacturing and application

Classification of composites

Composite materials

Matrices

Polymer Matrix Composites (PMC)

Metal Matrix Composites

(MMC)

Ceramic Matrix Composites (CMC)

4

Page 5: Polymer Matrix Composites (PMC) Manufacturing and application

A large molecule (macromolecule) composed of repeating structural units (monomer) typically connected by covalent chemical bonds.

Polymer & Polymer matrix composite

• Polymer :

5

Page 6: Polymer Matrix Composites (PMC) Manufacturing and application

Consisting of a polymer (resin) matrix and fiber. Very popular due to their low cost and simple fabrication

methods.

Polymer & Polymer matrix composite

• Polymer Matrix Composite (PMC):

6

Page 7: Polymer Matrix Composites (PMC) Manufacturing and application

Classification of Polymers

7

Page 8: Polymer Matrix Composites (PMC) Manufacturing and application

Thermosetting and Thermoplastics Polymers

Thermosetting PolymersExtensive crosslinking formed by covalent bonds.

High Thermal stability.

High dimensional stability.

Low weight.

High rigidity.

Can not be recycled due to its heavy covalent bonds.

Thermoplastics

No chemical linking between

individual molecules.

Molecules are bonded by weak secondary bonds like Van der walls bonds and hydrogen.

Parts can be made and joined by heating.

Can be remolded, and recycled.

Better toughness and impact resistance than thermosets.

8

Page 9: Polymer Matrix Composites (PMC) Manufacturing and application

Fibers in PMCs:

• Principal fiber materials in FRPs are glass, carbon, and Kevlar 49.

• Less common fibers include boron, SiC, Al2O3 and steel.

• Glass (in particular E glass) is the most common fiber material in today's ‑FRPs; its use to reinforce plastics dates from around 1920.

Various forms: Discontinuous (chopped)Continuous or woven as a fabric

Fibers used

9

Page 10: Polymer Matrix Composites (PMC) Manufacturing and application

Polymer Processing Forming Processes for Thermosetting matrix composites:

Pultrusion. Resin transfer molding. Hand layup and spray up techniques. Filament winding. Autoclave molding.

Forming Processes for Thermoplastic matrix composites:

Injection molding. Diaphragm forming. Film stacking. Thermoplastic tape laying. 10

Page 11: Polymer Matrix Composites (PMC) Manufacturing and application

Manufacturing Process of thermosetting polymers:

Pultrusion:

Pultrusion is a process where composite parts are manufactured by pulling layers of fibers/fabrics, bathed with resin, through a heated die, thus forming the desired cross-sectional shape with no length limitation.

11

Page 12: Polymer Matrix Composites (PMC) Manufacturing and application

Fibers are pulled from a set of fiber creels and through a resin bath. It then pass through a performer which gives it required cross sectional shape. The F & C dies finalize the required shape & remove excess resin & cure the composite so that it can be cut into required length.

Pultrusion process:

12

Page 13: Polymer Matrix Composites (PMC) Manufacturing and application

Pultrusion process:

13

Page 14: Polymer Matrix Composites (PMC) Manufacturing and application

Pultrusion process:

14

Page 15: Polymer Matrix Composites (PMC) Manufacturing and application

Advantages:

High volume productivity

Rapid processing

Low material scrap rate

Good quality control

Potential Problems:

Improper fiber wet-out

Fiber breakage

Die jamming

Complex die design

Pultrusion process:

15

Page 16: Polymer Matrix Composites (PMC) Manufacturing and application

Applications Uses as Panels, Beams, Ladders

Tool Handles,

Electrical Insulators,

Light poles, Hand rails, Roll-up doors etc

Pultrusion process:

16

Page 17: Polymer Matrix Composites (PMC) Manufacturing and application

Resin Transfer Molding In the RTM process, dry reinforcement is pre-shaped and oriented into

skeleton of the actual part known as the preform which is inserted into a heated matched die mold .

The heated mold is closed and the liquid resin is injected.

The part is cured in mold.

Finally mold is opened and part is removed from mold.

17

Page 18: Polymer Matrix Composites (PMC) Manufacturing and application

Advantages

Large complex shapes and curvatures can be made easily.

High level of automation.

Simpler than in manual operations.

Takes less time to produce.

Low volatile emission

Cost effective.

Low skill labor required

Resin Transfer Molding

18

Page 19: Polymer Matrix Composites (PMC) Manufacturing and application

Disadvantages

• Mold design is complex.

• Requires Mold-filling Analysis.

• Fiber reinforcement may Move during resin transfer.

Resin Transfer Molding

19

Page 20: Polymer Matrix Composites (PMC) Manufacturing and application

Application:

Resin Transfer Molding

• Wind Turbine blade.• Ship body.• Car body.• Truck panel.

20

Page 21: Polymer Matrix Composites (PMC) Manufacturing and application

Manufacturing Process of thermoplastics polymers:

Injection Molding

• Closed Mold process • Polymer is Mixed with very short reinforcing fibers (10- 40%) • Polymer-fiber mixture in form of pellets is fed through a hopper. • The material is then conveyed forward by a feeding screw and forced into a split mold, filling its cavity through a feeding system with sprue gate and runners.

21

Page 22: Polymer Matrix Composites (PMC) Manufacturing and application

Injection Molding (CONT.)

• Reciprocating screw since it not only rotates but also moves forward and backward according to the steps of the molding cycle. • It acts as a ram in the filling step.• then retracts backward in the molding step. • Heating elements, placed over the barrel, soften and melt the polymer. • The mold is equipped with a cooling system providing controlled cooling and solidification of the material.

Cooling channel

22

Page 23: Polymer Matrix Composites (PMC) Manufacturing and application

Injection molding machine

23

Page 24: Polymer Matrix Composites (PMC) Manufacturing and application

Injection Molding Machine

24

Page 25: Polymer Matrix Composites (PMC) Manufacturing and application

Advantages

INJECTION MOLDING

o Process can be fully automatedo High productivity & qualityo Price less low

25

Page 26: Polymer Matrix Composites (PMC) Manufacturing and application

DIAPHRAGM FORMING

• Diaphragm forming uses sheets of reusable silicon as a carrier for Thermopreg fabrics between a heating section and a forming section.• Process needs very low air pressure.• Inserting Thermopreg fabrics between two silicon sheets.

26

Page 27: Polymer Matrix Composites (PMC) Manufacturing and application

• Silicon/Thermopreg sandwich is placed in the hot platen equipment until it reaches a temperature of 210 ºC • Then its placed over forming machine and vacuum is created in the

lower site & pressed from upper site• Transfer the forming unit and apply positive air below 100 ºC.

DIAPHRAGM FORMING

27

Page 28: Polymer Matrix Composites (PMC) Manufacturing and application

Diaphragm Forming Machine

28

Page 29: Polymer Matrix Composites (PMC) Manufacturing and application

ADVANTAGES:

Components with double curvatures can be formed.

Compliant diaphragm do the job for simple components.

DIAPHRAGM FORMING

29

Page 30: Polymer Matrix Composites (PMC) Manufacturing and application

Types of processing discussed at a glance

30

Page 31: Polymer Matrix Composites (PMC) Manufacturing and application

APPLICATIONS OF PMCs

Aerospace and Military Aircraft

The aerospace industry is estimated to consume about 50 percent of advanced composites production in the United States.

The primary matrix materials used in aerospace applications are epoxies, and the most common reinforcements are carbon/graphite, aramid (e.g. Kevlar), and high-stiffness glass fibers.

Compared with metals, the principal advantages of advanced composites in aerospace applications are their superior specific strength and stiffness, resulting in weight savings of 10 to 60 percent over metal designs.

31

Page 32: Polymer Matrix Composites (PMC) Manufacturing and application

APPLICATIONS OF PMCsAerospace and Military Aircraft

Composites in Boing 787 body32

Page 33: Polymer Matrix Composites (PMC) Manufacturing and application

Automotive Industry The principal motivation for introducing PMCs is cost savings

Because the industry is mature and highly competitive.

Because of greatly improved corrosion resistance PMC automobiles could last 20 or more years compared to the current average vehicle lifetime.

APPLICATIONS OF PMCs

33

Page 34: Polymer Matrix Composites (PMC) Manufacturing and application

APPLICATIONS OF PMCs

Automotive Industry

34

Page 35: Polymer Matrix Composites (PMC) Manufacturing and application

Construction

A potentially high-volume market for PMCs lies in construction applications especially in.. Construction of

Buildings Bridges Housing Lampposts Smokestacks Highway culverts.

APPLICATIONS OF PMCs

The smith road bridge all-composites bridge, Ohio, USA

35

Page 36: Polymer Matrix Composites (PMC) Manufacturing and application

Medical Devices

The impact of PMCs on orthopedic devices such as

Hips

Knees

bone plates,

intramedullary nails is expected to be especially significant.

APPLICATIONS OF PMCs

36

Page 37: Polymer Matrix Composites (PMC) Manufacturing and application

Advantages of PMC

Good inplane stiffness and strength.

Low density.

Relatively low cost.

Corrosion resistance.

Low coefficient of thermal expansion.

Relatively mature technology.

Excellent in-service experience.

37

Page 38: Polymer Matrix Composites (PMC) Manufacturing and application

Limitations of PMC

Low maximum working temperature.

Sensitivity to radiation and moisture.

Processing temperature are generally higher than

those with thermosets.

Required special processing equipment.

Thermoset resins have poor impact resistance.

38

Page 39: Polymer Matrix Composites (PMC) Manufacturing and application

Conclusion

In 21st century we are in need of light but stronger materials. From automobile to aerospace, medical , military technology and even in household we need heavy duty, corrosion resistant material. Here comes the composites with all those specifications. And day by day the field of composite materials is getting stronger. Among all the composites Polymer Matrix Composites (PMC) have a strong place due to its specialization.

39

Page 40: Polymer Matrix Composites (PMC) Manufacturing and application

Thank You

40