Fiberglass and Glass Technology Frederick T. Wallenberger · Paul A. Bingham Editors Fiberglass and Glass Technology Energy-Friendly Compositions and Applications 123 Editors Frederick T. Wallenberger Paul A. Bingham Consultant Department of Engineering Materials 708 Duncan Avenue University of Sheffield Apartment 1108 Sir Robert Hadfield Building Sheffield S1 3JD Pittsburgh, Pennsylvania 15237 United Kingdom United States p.a.bingham@sheffield.ac.uk [email protected] ISBN 978-1-4419-0735-6 e-ISBN 978-1-4419-0736-3 DOI 10.1007/978-1-4419-0736-3 Springer New York Dordrecht Heidelberg London Library of Congress Control Number: 2009938639 © Springer Science+Business Media, LLC 2010 All rights reserved. This work may not be translated or copied in whole or in part without the written permission of the publisher (Springer Science+Business Media, LLC, 233 Spring Street, New York, NY 10013, USA), except for brief excerpts in connection with reviews or scholarly analysis. Use in connection with any form of information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilar methodology now known or hereafter developed is forbidden. The use in this publication of trade names, trademarks, service marks, and similar terms, even if they are not identified as such, is not to be taken as an expression of opinion as to whether or not they are subject to proprietary rights. Printed on acid-free paper Springer is part of Springer Science+Business Media (www.springer.com) Preface This book offers a comprehensive view of fiberglass and glass technology with emphasis on energy-friendly compositions, manufacturing practices, and appli- cations, which have recently emerged and continue to emerge. Energy-friendly compositions are variants of incumbent fiberglass and glass compositions. They are obtained by reformulation of incumbent glass compositions in order to reduce the melt viscosity and increase the melting rate, thereby saving process energy and reducing environmental emissions. As a result, new energy-friendly compo- sitions are expected to become a key factor in the future for the fiberglass and glass industries. The contributors to the book consist of both academic and industrial sci- entists. This book is therefore dedicated to those in the academic and industrial community who seek an understanding of the past in order to make progress in the future. This book consists of three interrelated sections. Part I reviews a wide range of continuous glass fibers, their compositions, and properties. Dr. F. T. Wallenberger authored Chapter 1, which reviews important glass fibers ranging from commercial 100% SiO2 glass fibers and commercial multi-oxide glass fibers to experimen- tal glass fibers containing 81% Al2O3. Dr. Wallenberger also authored Chapter 2. This chapter offers a new method (trend line design) for designing environmentally and energy-friendly E-, ECR-, A-, and C-glass compositions to reduce the process energy by compositional reformulation. Few fiberglass applications are based on yarns; most are based on composites. Dr. J. H. A van der Woude and Dr. E. L. Lawton authored Chapter 3, which reviews fiberglass composite engineering with an important sub-chapter on windmill blade construction. Dr. A. V. Longobardo wrote Chapter 4. It reviews the glass fibers which became available as reinforce- ment for printed circuit boards and analyzes their compositions as well as the needs of the market. Finally Dr. R. L. Hausrath and Dr. A. Longobardo authored Chapter 5, which reviews high-strength glass fibers and analyzes existing and emerging markets for these products. Part II of the book deals with soda–lime–silica glass technology. The first two chapters (Chapters 6 and 7) parallel the first two chapters in Part I (Chapters 1 and 2). Dr. Ing. A. Smrcekˇ wrote Chapter 6. It is devoted to a wide range of industrial flat, container, and technical glass compositions and to an in-depth review of their properties. Dr. P. A. Bingham authored Chapter 7. It deals with the design of new v vi Preface energy-friendly flat, container, and technical glass melts through reformulation of existing compositional variants to reduce the process energy. Part III of the book deals with emerging glass melting science and technology, and is conceptually applicable to both glass and fiberglass melts. Prof. Dr. H.-J. Hoffmann authored Chapter 8, which offers new insights into the basics of melt- ing and glass formation at the most fundamental level. Prof. Dr. R. Conradt wrote Chapter 9, which deals with the thermodynamics of glass melting, offers a model to predict the thermodynamic properties of industrial multi-component glasses from their chemical compositions, addresses the role of individual raw materials in the melting process of E-glass, and facilitates the calculation of the heat of the batch-to- melt conversion. Prof. Dr. H. A. Schaeffer and Priv. Doz. Dr.-Ing. H. Müller-Simon authored Chapter 10, which reviews the use of in situ sensors for monitoring glass melt properties and monitoring species in the combustion space and also reviews redox control of glass melting with high levels of recycled glass to enhance the environmentally friendly value of the resulting glass. Dr. R. Gonterman and Dr. M. A. Weinstein authored Chapter 11, which deals with the recently emerging plasma melt technology and its potential applications. Dr. Wallenberger wishes to acknowledge his years at PPG Industries from 1995 to 2008, especially the invitation he received from the late John Horgan, Vice President, Fiberglass, to join PPG, and the support of Dr. Jaap van der Woude, who as Director of Research, encouraged him in 1997 to pursue innovative com- positional fiberglass research. Dr. Wallenberger gratefully acknowledges the help of Dr. Bingham, co-editor of the book, and the valuable contributions of the chapter authors. Finally, Dr. Wallenberger wishes to acknowledge the thoughtful support of Jennifer Mirski who, as assistant editor, Springer Publisher, helped in editing the entire book. Dr. Bingham wishes to thank the following people for their help, insight, com- ments, and encouragement: Dr. Fred Wallenberger, co-editor of the book; Prof. Michael Cable for many interesting discussions; all of our contributing authors; colleagues present and past at the Society of Glass Technology, the University of Sheffield, and the British Glass Manufacturer’s Confederation; and the many other individuals with whom he has held discussions over the years on the fascinating subject of glass. Finally and most importantly, he thanks his family for their endless patience, love, support, and encouragement. F. T. Wallenberger Pittsburgh, PA, USA P. A. Bingham Sheffield, UK About the Editors Dr. Frederick T. Wallenberger was an instructor in Chemistry at Fordham University (1957–1958), a research fellow at Harvard (1958–1959), and a scientist at DuPont Fibers, Pioneering Research Laboratory (1959–1992). He retired in 1992 from DuPont and became a research professor (Materials Science) at the University of Illinois in Urbana-Champaign (1992) and a visiting professor (Textiles) at the University of California in Davis (1994). He joined PPG as a staff scientist in 1995, retired in 2008, and serves as a consultant now. He studied the relationships between structures, properties, and value-in-use of new materials and contributed to the commercialization of new fibers through “intrapreneurial” research, project management, and technology transfer. He is an expert in the fields of advanced glass fibers, ceramic fibers, carbon fibers, natural fibers, polymer fibers, single crystal fibers, and composites. Dr. Wallenberger has over 150 papers in the refereed scientific literature, includ- ing three in the journal science, edited four books (Advanced Inorganic Fibers, 1999; Advanced Fibers, 2002; Natural Fibers, 2004; and Fiberglass and Glass Technology, 2009), wrote two recent review articles (Introduction to Reinforcing Fibers and Glass Fibers, ASM Handbook on Composites, 2002), and received 10 US Patents. He chaired three major symposiums (“Chemistry and Environment,” American Chemical Society, 1974; “Advanced Fibers, Plastics and Composites,” Materials Research Society, 2001; “Behavior of Glass Melts,” Gordon Research Conference, 2005), gave three invited Gordon Research Conference lectures (“Aramid Fibers,” 1964; “Foamed Polyester Fibers,” 1975; and “Glass Fibers,” 1992) and wrote the first review article that included KevlarTM (“The Chemistry of Heat Resistant Polymer Fibers,” Angewandte Chemie, 1964) Dr. Wallenberger received the Environmental Respect Award from DuPont (1992). He is a member of the Association of Harvard Chemists (1958–) and was elected a Fellow of the American Ceramic Society (2005). His biography appears in several standard references including Who’s Who in the World, Who’s Who in America, and Who’s Who in Science and Engineering. Dr. Paul A. Bingham received his BEng (Hons) degree in Materials Science and Engineering from the University of Sheffield in 1995. He then studied toward a Ph.D. (1995 to 1999, thesis title “The Environment of Iron in Silicate Glasses”) at vii viii About the Editors the same institution, which hosts one of the world’s premier glass science depart- ments. From 1999 to 2003 he was employed as a technologist by Glass Technology Services Ltd (GTS) a subsidiary of the British Glass manufacturers confederation where he carried out a wide range of glass and ceramic-related R&D, project man- agement, and industrial production problem solving. He was