Design Data for Reinforced Plastics
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DESIGN DATA FOR REINFORCED PLASTICS This book is dedicated to Margaret, Mark and Duncan and Pauline, David and Helen DESIGN DATA FOR REINFORCED PLASTICS A guide for engineers and designers Neil L. Hancox Project Manager AEA Technology Harwell, UK and Rayner M. Mayer Consultant Sciotech Yateley, UK SPRINGER-SCIENCE+BUSINESS MEDIA, B.V. First edition 1994 © 1994 Rayner M. Mayer Originally published by Chapman & Hall in 1994 Softcover reprint of the hardcover 1st edition 1994 Typeset in Sabon 10.5/12.5 by Best-set Typesetter Ltd, Hong Kong ISBN 978-94-010-4304-5 Apart from any fair dealing for the purposes of research or private study, or criticism or review, as permitted under the UK Copyright Designs and Patents Act, 1988, this publication may not be reproduced, stored, or transmitted, in any form or by any means, without the prior permission in writing of the publishers, or in the case of reprographic reproduction only in accordance with the terms of the licences issued by the Copyright Licensing Agency in the UK, or in accordance with the terms of licences issued by the appropriate Reproduction Rights Organization outside the UK. Enquiries concerning reproduction outside the terms stated here should be sent to the publishers at the London address printed on this page. The publisher makes no representation, express or implied, with regard to the accuracy of the information contained in this book and cannot accept any legal responsibility or liability for any errors or omissions that may be made. A catalogue record for this book is available from the British Library Library of Congress Cataloging-in-Publication data Hancox, N.L. Design data for reinforced plastics: a guide for engineers and designers/Neil Hancox and Rayner M. Mayer. - 1st ed. p. cm. Includes index. ISBN 978-94-010-4304-5 ISBN 978-94-011-0707-5 (eBook) DOI 10.1007/978-94-011-0707-5 1. Fiber reinforced plastics. I. Mayer, Rayner M. II. Title. TA455.P5H34 1993 620.1'923—dc20 93-12190 CIP Printed on permanent acid-free text paper, manufactured in accordance with the proposed ANSI/NISO Z 39.48-199X and ANSI Z 39.48-1984 CONTENTS Preface Vlll Layout of the book lX How to use this book x Acknowledgements Xl Trademarks and registered trade names Xlll Glossary xv Units XXll Fabric notation XXlV 1 Design considerations 1 1.1 Introduction 1 1.2 Layout of the book 3 1.3 Choice of data 4 1.4 Composites behaviour 5 1.5 Conclusion 13 1.6 Reference information 13 2 Material selection and data assessment 14 Summary 14 2.1 Introduction 14 2.2 Material constituents 14 2.3 Material selection 16 2.4 Data assessment 30 2.5 Test methods and standards 31 2.6 Data reduction and presentation 31 2.7 Use of data in design 32 2.8 Reference information 32 3 Properties 35 Summary 35 3.1 Introduction 35 3.2 The role of fibre and matrix 36 3.3 Fibre properties 38 3.4 Physical form of the reinforcement 46 3.5 Matrix properties 48 3.6 Composite properties 50 3.7 Design and manufacture 53 3.8 Health and safety 54 3.9 Reference information 54 V Contents 4 Mechanical properties of random and fabric-reinforced resins 55 Summary 55 4.1 Introduction 55 4.2 Polyester resins 57 4.3 Vinyl ester resins 71 4.4 Phenolic resins 75 4.5 Epoxy resins 84 4.6 Other resins 92 4.7 Design strategy 94 4.8 Reference information 95 5 Mechanical properties of aligned fibre composites 96 Summary 96 5.1 General information 96 5.2 Glass fibres 97 5.3 Aramid fibres 106 5.4 Carbon fibres 115 5.5 Material selection and design strategy 132 5.6 Reference information 132 6 Impact and fracture 133 Summary 133 6.1 Introduction 133 6.2 Impact 138 6.3 Fracture 148 6.4 Design strategy 152 6.5 Reference information 152 7 Thermal and electrical properties 153 Summary 153 7.1 Thermal properties 153 7.2 Electrical properties 163 7.3 Design strategy 169 7.4 Reference information 169 8 Fire performance 170 Summary 170 8.1 Introduction 170 8.2 Non-combustibility 172 8.3 Ignitability 173 8.4 Flame spread 174 8.5 Rate of heat release 181 8.6 Smoke and toxic gas emissions 182 8.7 Flash-over 189 8.8 Design strategy 191 Vl 8.9 Reference information 192 Contents 9 Environmental effects 195 Summary 195 9.1 Introduction 195 9.2 Effect of moisture 197 9.3 Corrosion resistance 209 9.4 Hardness, abrasion and weathering 217 9.5 Design strategy 225 9.6 Reference information 225 10 Creep and fatigue 226 Summary 226 10.1 Introduction 226 10.2 Creep 229 10.3 Time-temperature superposition 236 10.4 Fatigue 238 10.5 Design strategy 266 10.6 Reference information 268 11 Influence of processing on properties 269 Summary 269 11.1 Introduction 269 11.2 Contact moulding 271 11.3 Resin transfer moulding 275 11.4 Press moulding 278 11.5 Prep reg moulding 284 11.6 Pultrusion 286 11.7 Filament winding 290 11.8 Recycling 293 11.9 Design strategy 294 11.10 Reference information 294 12 Quality assurance 296 Summary 296 12.1 Introduction 296 12.2 Incoming materials 297 12.3 Processing 300 12.4 Non-destructive evaluation 304 12.5 Destructive testing 308 12.6 Strategy for quality control 313 12.7 Reference information 313 Index 315 Vll PREFACE Fibre-reinforced plastics are a group of materials whose properties can only be determined after a component or structure has been fabricated. This poses both a challenge and an opportunity for those who would use these materials: • a challenge because one has to surmise or assume a certain set of properties in order to undertake the design; • an opportunity because it is possible to place the reinforcement so that it balances the imposed loads exactly. This book addresses the challenge, because the data required for design are scattered far and wide and are not otherwise available in a form in which they can be used directly. The assembled data are believed to be characteristic of the principal materials used for general purpose mechanical engineering. This book is neither a compendium nor a database and so where gaps appear it is either because the data do not exist, or the authors have been unable to locate them. If this book is found to be useful, then we hope that others may be encouraged to fill the gaps in our knowledge or submit data, which could be used in subsequent editions. Whilst the book is self-contained, the accompanying volume on design principles (Mayer, R.M. (ed.) (1993) Design with Reinforced Plastics, Design Council, London) may need to be consulted if readers are not acquainted with the design process. If this book helps to encourage others to design with these materials, then the authors' labours will have been well rewarded. Rayner Mayer Yateley and Neil Hancox Abingdon, June 1993. V1l1 LAYOUT OF THE BOOK The first three chapters discuss the primary design considerations, the material selection process for composites and the properties of the basic constituents. These chapters should enable the designer to establish a broad perspective of what might be possible when such constituents are incorporated to form a composite. Data on short-term mechanical properties of composites are presented in the next three chapters. A clear distinction is made between random, fabric and aligned reinforcement and the properties that these produce. A further four chapters consider properties associated with the perfor mance of a composite under various conditions, including the effects of impact, fire, environmental conditions and long-term loading, either continuous or cyclic. Each of the major manufacturing processes is briefly described, together with a listing of the relevant data location. Quality control of processing is discussed in the final chapter. IX HOW TO USE THIS BOOK This book can be used in various ways: For readers conversant with composites, key words or locators, placed in the margin, enable data to be located. The search may either be for a suitable material, or for a required property level. If more basic information is required first, Chapter 2 should be consulted for the initial selection of constituents and Chapter 3 for specific properties of fibres and resins. Resin properties are amplified further in Chapter 4. The classification of mechanical properties is by resin type in Chapter 4 and by fibre type in Chapter 5. This is consistent with the way in which the materials are used. The influence of processing on both material selection and properties is discussed in Chapter 11, and may restrict the choices set out in Chapters 4 and 5. Chapters 6 to 10 describe other properties which need to be considered as part of the design process, whilst Chapter 12 outlines aspects of quality assurance to ensure compliance with the design. If, as is often necessary, the design has to be iterated, then the material selection may need to be reconsidered, and the available data reviewed. Databases and manufacturers' information can be used to supplement what is set out here. DISCLAIMER The data here are provided in good faith, but neither we nor the original providers of the data are able to accept responsibility for the accuracy of any of the information included, or for any of the consequences that may arise from use of the data or designs or constructions based on any of the information supplied or materials described.