03.CompoundingOfPolymers&Composites (71) (NXPowerLite)

8/13/2019 03.CompoundingOfPolymers&Composites (71) (NXPowerLite)

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Compounding of Plastics &Composites


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Compounding

Alloying Blending

Difference?

Filling / Adding


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Compounding

Alloying Blending

Single Tg

SynergisticProperties

Multiple Tg

Average ofProperties


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Additives, Fillers & Extenders?


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Additives, Fillers & Extenders?

Additives.Fillers.Extenders

Quality .Quantity

More Cost.Less


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Additives and Fillers:

To change and improve

1.Physical

2.Mechanical

3.Processing properties


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Additives and Fillers:

1.Colorants

2.Plasticizers

3.Flame retardants

4.Antistatic agents5.Heat Stabilizers

6.Anti-oxodants

7.UV Light Absorbers

8.Blowing Agents9.Coupling Agents

10.Fillers


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1.Additives:COLORANTSProvide colour-fastness when exposed to

light, temperature, humidity, chemicals

Without reducing other properties like Flow

during processing, Resistance to chalking &

Impact strength


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2. Additives:

PLASTICIZERS


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2.Additives: PLASTICIZERS

Enhance flexibility, resiliency, & melt flow ofplastics

Act like internal lubricants by reducing Vander-

Waals forces between polymer chains & bypreventing them from intermeshing


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LUBRICANTS:Enhance resins

Processabilty & Appearance of final product


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3.Additives:

FLAME RETARDANTS


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3.Additives: FLAME RETARDANTS

Reduce flammability of plastics

Insulate plastic, create endothermic cooling

reaction, coat plastic excluding oxygen


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4.Additives:

ANTISTATICAGENTS

(De-staticizers)

Reduce build up of

electrostatic charges on

surface of plastics


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5. Additives:

HEAT STABILIZERS

Prevent degradation of resins during

processing when melts subjected to high

temperatures


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7. Additives:UV LIGHT ABSORBERSstabilize colour & lengthen life of product

because virtually every plastic degrades insun-light through discoloration & loss of

physical properties

Years of

outdoor

Exposure


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8. Additives:BLOWING AGENTS

Produce cellular / foam

structure in a plastic mass


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9. Additives:

COUPLING

AGENTS

Improve

bonding of plasticto inorganic filler

materials, such

as glass fibres

Silicones and

Titanates usedMagneto Cover Story


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10. Additives:

FILLERS

Inorganic (e.g: Glass fibres )

Organic (e.g:wood)

Mineral (e.g: Calcium Carbonate, Silica & Clay)

Used with thermosetting resins Like Phenolics,

Ureas and Melamines


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Because Properties of extended plastic often

decrease, use limited to less critical

applications

One of the most widely used filler is wood

flour (Which country?)

Maple Flour


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Polymer Composites


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Objective of Capsule:

What are composites

Why do we need compositesTypical Applications


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Composite: Any material made of more

than one component


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+ 4 + 5?

1

2

3


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1.Composite?

2.Macintosh?
http://inflatablesunway.en.alibaba.com/product/50122059/50556781/Advertising_Balloons/Balloons/showimg.html


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Macintosh

Why do we make composites? To make a material

that has the properties of both its components.

We combine the water-resistance of Polyisoprene and the

comfort of Cotton.


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Composite

Fibre Matrix


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Composite

Fiber Matrix

Glass /

Kevlar /

Carbon /PE

TS/

Epoxy /

Polyimide


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Composites

Fibre ReinforcedParticle Based

Laminar

e.g: FERAL, Plywood, ARAL,


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Particulates:

Spheres

Rods

Flakes

Aspect Ratio ~1


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Composite Properties affected by:

Size, Shape

Amount & Distribution

Modulus


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Fiber Composites

Long FiberShort Fiber

Discontinuous Continuous

Relationship between Modulus & Length


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PlywoodMDFBoard

Particle

Board

Isotropy(Random

Particulate)

AnisotropyOrthotropyProperties

(Aligned

Short fiber)

(Continuous

Fiber)


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Fiber embedded in the matrix in order to make the

matrix stronger

Advantages of Fiber Reinforcement in cars

Strong and light

Stronger than steel, but weigh much less

Can be used to make automobiles lighter

More fuel efficient

Pollute less

Wh t Fib D ?


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What Fibers Do?

Fiber-reinforced composite Fiberglas

Pour mix of Styrene & Polyester over mass of

glass fibers

Styrene & double bonds in polyester react by

Polymerization to form cross-linked resin

Glass fibers trapped inside, acting as

reinforcement


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Fibers not lined up in any

particular direction

Tangled mass

We can make composite

stronger by lining up allfibers in same direction


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Any suggestion to make it strong in bothdirections?


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What does the matrix do for fiber?

Why not just use fibers by themselves?

1.Function of Matrix

Matrix holds the fibers together

Loose bundle of fibers wouldn't be of much use


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2. Function of Matrix

Though fibers are strong, they can be brittle

Matrix can absorb energy by deforming under

stress.(i.e) matrix adds toughnessto composite


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3.Function of Matrix

While fibers have good tensilestrength, they

usually have low compressivestrengthThat is, they buckle when you squash them

Matrix gives compressive strength to composite


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Why Glass Fiber?

EconomicalAs fiber, strong & flexible!


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Properties of Glass Fibers

Glass

Grade

Sp.

Gravity

Tensile

StrengthMPa

Tm0

C

Applications

A ?

E ?

ECR ?

S ?


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Glass

Grade

Sp.

Gravity

Tensile

StrengthMPa

Tm0

C

Applications

A 2.50

E 2.58

ECR 2.62

S 2.48


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Glass

Grade

Sp.

Gravity

Tensile

StrengthMPa

Tm0

C

Applications

A 2.50 3040

E 2.58 3450

ECR 2.62 3625

S 2.48 4590


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Glass

Grade

Sp.

Gravity

Tensile

StrengthMPa

Tm0

C

Applications

A 2.50 3040 996

E 2.58 3450 1065

ECR 2.62 3625 1204

S 2.48 4590 1454


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Glass

Grade

Sp.

Gravity

Tensile

StrengthMPa

Tm0

C

Applications

A 2.50 3040 996 Good Chem.

Resistance

E 2.58 3450 1065 Electrical Grade

(PCB)

ECR 2.62 3625 1204 Elec.+ Chem.

S 2.48 4590 1454 Strength + ThermalStability (Air-craft)

C Grade


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C Grade

Coupling Agent

Imparts lubricity

Resin Compatibility

Dimensional Stability

Adhesion with Matrix

Protection from handling damage


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Fire-Proof Kevlar West

Carbon fiber >KevlarWrt UTS


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Spectra


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Spectra

Strongest, lightest man-made fiber

Bullet resistant composite

10 times stronger than steel

40 percent stronger than aramids

Light enough to float on water

Exhibits superior resistance to chemicals,Water

and UV lightExcellent vibration dampening,flex fatigue and

internal fiber-friction characteristics

Spectra fibers are used in


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Spectra fibers are used in

Police and military ballistic vests

Helmets and armored vehiclesSailcloth

Fishing lines

Cut-resistant gloves

Safety apparel


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M i d l & f i


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Matrix needs only to wet & form a continuous

phase around the reinforcement


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Applications of Composites


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Mag - Graphite Composite Tennis Racquet


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Should be


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Should be

As light as possible

As strong as possible

Can bend but should not break
http://images.google.co.in/imgres?imgurl=http://www.r-store4u.com/tweak/images/336313.jpg&imgrefurl=http://www.r-store4u.com/rti/showprod.cfm%3F%26DID%3D6%26User_ID%3D58992%26st%3D7138%26st2%3D88041833%26st3%3D-42933312%26CATID%3D290%26ObjectGroup_ID%3D1356&h=220&w=220&sz=3&hl=en&start=20&tbnid=hanvN90lzeJ5eM:&tbnh=102&tbnw=102&prev=/images%3Fq%3Dfishing%2Brod%2Bcomposite%26svnum%3D10%26hl%3Den%26lr%3D


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First Flight :4 January 2001


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Crew one (pilot)

Maximum speed:1.8 Mach

Range:850 km

Service ceiling:15,250 m

Length:13.20 m

Wingspan:8.20 m

Height:4.40 m

Weight

Empty:5,500 kg

Loaded:8,500 kg

LCA Tejas

Conclusion:


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Conclusion:

Generally Composites are characterized by:

1. Density

2. Specific strength

3. Specific Stiffness

4. High-temperature performance limits

5. Wear resistance

R l ti hi b t i ht & t?


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Relationship between weight & cost?

Weight

Cost

?

R l ti hi b t i ht & t?


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Relationship between weight & cost?

Weight

Cost

Automotive

Aero

Space


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Think Composites
http://www.aperfectworld.org/clipart/cartoons/smiley01.gif


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Thank You

pgschool@nttf co in
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Documents

03.CompoundingOfPolymers&Composites (71) (NXPowerLite)