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Compression Molding Composites 201 John P. Busel, F.ACI, HoF.ACMA VP, Composites Growth Initiative American Composites Manufacturers Association 2 Objectives of Session • To build on the information presented in Composites 101 to provide: • a greater understanding of FRP composite materials and properties, and • options to manufacture composites • General guidelines in design of FRP composites products • Help answer the question – why composites. 3 September 21-24, 2020 / www.theCAMX.org Outline 1. Fiber Reinforcements 2. Polymers (matrix) 3. Manufacturing / Product and Process Characteristics 4. Designing with Composites 5. Recycling Composites 4 September 21-24, 2020 / www.theCAMX.org Composites 101 – An Overview From the ACMA CCT Program, Composites defined as: • “A combination of reinforcement fiber in a polymer resin matrix, whereas the reinforcement has an aspect ratio that enables the transfer of loads between fibers, and the fibers are chemically bonded to the resin matrix”. – A combination of fiber in a polymer matrix – A resin matrix reinforced with a fiber • The reinforcement has an aspect ratio that enables the transfer of loads between fibers – The fibers are long and narrow, and where they overlap the polymer matrix transfers loads to the adjacent fibers • The fibers are chemically bonded to the resin matrix – There is adhesion between the fibers and matrix and the fibers do not move within their encapsulation when loaded 5 September 21-24, 2020 / www.theCAMX.org 1. Fiber Reinforcements 6 Constituent Components: Fibers Typical Composite Reinforcing Fibers: Glass • E-Glass (Alumina-calcium-borosilicate): – General purpose fiber with good strength and high electrical resistivity – Forms • Single end “direct draw” roving for fabric weaving, stitch-bonding, braiding, pultrusion, filament winding – From very fine yarn for electrical circuit boards to heavy roving for industrial composites • Multi-end “assembled” roving for chopped mat – Nomenclature and composition outlined in ASTM D578 – Typically named after sizing type – Select Products: • Hybon® 2026 (PPG/NEG), StarRov® (JM), 469L (CPIC), TD44C (Vetrotex) • ECR-Glass (Calcium aluminosilicate): – Boron oxide-free version of E-glass which increases acid corrosion resistance – Produced in same forms as E-glass – Select Products: • Advantex® (Owens Corning), E6CR™ 396 (Jushi) 7 September 21-24, 2020 / www.theCAMX.org Constituent Components: Fibers Typical Composite Reinforcing Fibers: Glass • A-Glass (Soda lime silicate): – Lower strength/durability fiber compared to E-glass, only in veil/mat format – Select Products: • Surmat® 200 veil (Superior Composites Co.) • H-Glass (Calcium aluminosilicate): – Higher strength and modulus version of ECR-glass fiber – Select Products: • Xstrand® H (Owens Corning) • R-Glass (Calcium aluminosilicate and Basalt): – Higher strength and modulus than H-glass fiber – Select Products: • INNOFIBER® Hybon® XM (PPG/NEG) • C-Glass (Calcium borosilicate): – Used for highly corrosive acidic environments, usually only in nonwoven veil format – Select Products: • C64 C-Veil (Owens Corning) 8 September 21-24, 2020 / www.theCAMX.org Constituent Components: Fibers Typical Composite Reinforcing Fibers: Glass • AR-Glass (Alkali zirconium): – Highly alkali resistant fiber used for cement and concrete reinforcement – Select Products: • Cem-FIL® (Owens Corning) • S-Glass (Magnesium aluminosilicate): – Higher strength and modulus fiber than R-glass, also very good high temperature and corrosion resistance – Select Products: • S-1 Glass™, S-2 Glass®, & S-3 Glass™ (AGY) • Quartz (99.99% Pure silica): – Highly expensive fiber with very low coefficient of thermal expansion (CTE) and superior electromagnetic properties (for radio frequency transparency – radomes) – Select Products: • Astroquartz® (JPS) , Quartzel® (Saint-Gobain) 9 September 21-24, 2020 / www.theCAMX.org Constituent Components: Fibers 10 September 21-24, 2020 / www.theCAMX.org Constituent Components: Fibers Typical Composite Reinforcing Fibers: PAN Based Carbon – The most widely available and utilized type is produced from a specially formulated polyacrylonitrile (PAN) precursor fiber • The PAN carbon fiber is generally classed in 3 different groups according to modulus – Standard Modulus (SM) / High Strength (HS) • Most widely used in industrial applications • Most cost effective – Intermediate Modulus (IM) • Best blend of strength/modulus, • Typically used in aerospace/defense applications – High Modulus (HM) • Highest stiffness, lowest CTE, highest conductivity, & lower strength than SM & IM versions, highest cost, • Typically used in space craft/satellites/sporting equipment 11 September 21-24, 2020 / www.theCAMX.org Constituent Components: Fibers Tensile Modulus* Tensile Strength* Classification Msi GPa ksi MPa Standard Modulus/High Strength 33-37 230-255 500-725 3,450-5,000 Intermediate Modulus 40-45 275-310 600-925 4,130-6,370 High Modulus 45-87 310-600 275-700 1,890-4,900 *Note: Carbon fiber modulus, strength, and elongation to beak are ideal values produced via impregnated strand testing and may not translate directly to the corresponding fabric/composite properties due to fiber misalignment, resin compatibility, and damage during processing 12 September 21-24, 2020 / www.theCAMX.org Constituent Components: Fibers Typical Composite Reinforcing Fibers: PAN Based Carbon Standard Modulus (SM) / High Strength (HS): • Small (1K) to Large (60K) tow sizes available, aerospace to industrial grade • Select Products: – Toray: T300, T700S & Zoltek (Subsidiary): Panex® 35; Toho-Tenax: HTA40; UTS50, Mitsubishi Chemical/Grafil: 34-700, TRH50; SGL: C T24, C T50; Hexcel: AS4, AS7; Solvay (Cytec): T-300 – Others: AKSA, Bluestar, Formosa, Hyosung, Dalian Xingke, GanSu HaoShi Intermediate Modulus (IM): • Smaller range of tow sizes (6K-24K), recent work on large tow industrial versions (ORNL) • Select Products: – Toray: T800H, T1000G; Toho-Tenax: IMS40, IMS65; Mitsubishi Chemical/Grafil: MR40, MR 60H; Hexcel: IM7, IM10; Solvay (Cytec): T-650; Formosa: T-42 High Modulus (HM): • Small range of tow sizes (3K-12K) • Select Products: – Toray: M40J, M60J; Toho-Tenax: UMS40, HMA35; Mitsubishi Chemical/Grafil: HR 40, HS 40; Formosa: TC55 13 September 21-24, 2020 / www.theCAMX.org Constituent Components: Fibers Typical Composite Reinforcing Fibers: Pitch Based Carbon • Precursor material is by-product of fossil fuel processing: – Coal & Petrol Tar (i.e. Pitch) • Isotropic: Typically low modulus, used for thermal management applications • Mesophase Pitch: (made by polymerizing isotropic pitch to a higher molecular weight) – Highly aligned carbon chains along fiber axis provide extremely high modulus, thermal conductivity and are called “Ultra High Modulus” (UHM) carbon or graphite fiber – 1K-16K tow sizes typically available – There has been work on lower cost precursor (ref. CompositesWorld) – Applications: aerospace, civil engineering (concrete strengthening), sports – golf shafts • Select Products: – Mitsubishi Chemical: DIALEAD® K63712, K13C2U – Nippon Graphite Fiber: GRANOC YSH-50A-10S, YS-80A-60S Tensile Modulus* Tensile Strength* Classification Msi GPa ksi MPa Ultra High Modulus 75-136 520-935 375-550 2,600-3,800 *Note: Carbon fiber modulus, strength, and elongation to beak are ideal values produced via impregnated strand testing and may not translate directly to the corresponding fabric/composite properties due to fiber misalignment, resin compatibility, and damage during processing 14 September 21-24, 2020 / www.theCAMX.org Constituent Components: Fibers Typical Composite Reinforcing Fibers: Polymer Based • Para-Aramid: – Low density and high strength with high impact and fatigue resistance – Fiber exhibits a “soft” failure mode in that it doesn’t shatter upon impact or flexing – Has UV and moisture absorption issues – For composites, use the “high modulus” versions: K49, K149, & T2200, low modulus for ballistics (K29) – Select Products: • Kevlar® (Dupont) & Twaron® (Teijin) 15 September 21-24, 2020 / www.theCAMX.org Constituent Components: Fibers Typical Composite Reinforcing Fibers: Comparison FIBER PROPERTIES (IMPREGNATED STRAND) Tensile Tensile Fiber Elongation Density Cost Strength Modulus Type ksi Msi % lb/in3 E-Glass 290 to 360 10 to 10.5 3 to 5 0.092 to 0.094 $ E-CR Glass 320 to 375 11.75 3 to 5 0.095 $ H-Glass 350 to 420 13.00 3 to 5 0.094 $$ Glass R-Glass 440 to 493 13.00 5.35 0.092 $$$ S-Glass 495 to 555 13.25 5.50 0.089 $$$$ Basalt (R-Gl.) 392 to 464 12.34 to 13.79 3 to 5 0.096 $$$$ SM Carbon 500-725 34 to 37 1.5 to 2.0 0.065 $$$$$ IM Carbon 600 to 925 40 to 45 1.5 to 2.2 0.065 $$$$$$ Carbon HM Carbon 275 to 700 45 to 87 ~1.0 0.063 to 0.069 $$$$$$$ UHM Carbon 380 to 550 114 to 135 >1.0 0.070 to 0.078 $$$$$$$$ Aramid (K49) 525 16.30 2.4 0.052 $$$$$ Aramid Aramid (K149) 501 26.00 1.9 0.053 $$$$$$ 16 September 21-24, 2020 / www.theCAMX.org Constituent Components: Fibers Typical Composite Reinforcing Fibers: Polymer Based • Polypropylene: Innegra™ (Innegra Technologies) – Extremely (< 1.0 g/cc) low density polyolefin fiber with very good dynamic response characteristics – Fairly low mechanical properties, but a cost-effective alternative to para-aramid / UHMWPE / PBO/LCP fibers with better matrix resin bonding properties – Works well as a hybrid with more brittle fiber (i.e. carbon) for increased ductility and impact resistance • Ultra High Molecular Weight Polyethylene - UHMWPE: Spectra® (Honeywell) & Dyneema® (DSM) – Very low-density polyolefin fiber made of extremely long polymer chains of polyethylene –
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