Assignment01
Definition:
In materials science, a polymer matrix composite is a composite
material composed of a variety of short or continuous fibers bound together by a
matrix of organic polymers. PMCs are designed to transfer loads between fibers of
a matrix.
Explanation:
Composite materials are made by combining two different materials
having unique properties to achieve the best properties suitable for various
applications. Polymer matrix composite is one of the various types of composite
materials possessing its own properties for various applications. As composite
material is made by adding two phases that are matrix and reinforcement fibers, in
polymer matrix composites, polymers are taken in matrix phase and the other
suitable materials are taken in the form small fiber particles. Thermosetting resins
are the most widely used polymers in PMCs. Matrix material serve several
functions in the composites. They provide bulk form of product, hold the fiber
particles in place and distributes load uniformly throughout the matrix phase.
Commonly used reinforcement fibers are glass, carbon and Kevlar. Advanced
polymer matrix composites use boron, carbon, Kevlar as reinforcing fibers in with
epoxy as the matrix.
Application:
Polymer matrix composites are used in automotive industries which
benefits reduction in weight and also some time reduces the production cost of the
vehicle parts. Most common parts made by PMCs are exterior body panels,
components under the hood, battery trays and protective shields. In marine
application, the composites are for making power boats and sailing yachts. The
reason for the use of composites in marine application is relatively less cost as
compared to wood and metal work, less skill of operator and increased life time
with less damage to the manufactured parts. Because of various advantages the
Name: Zarnain khan Reg No: 20jzmec0388
Assignment01
composites are also used in aerospace applications which need needs high strength
and less weight.
Manufacturing processes of polymers matrix composites:
There are several manufacturing methods for processing polymer matrix
composites. The method selected based on type materials we select and application
required. The various methods are hand layup method, Spray-up molding,
Autoclave method, filament winding method and reaction molding.
Hand layup Method:
It a method in which the mold is prepared as one side open
with the required shape. The fibers of reinforcement are layed on the surface and
matrix material in the form of gel is painted over the fibers. This painting is
continued until the required thickness is obtained. It is the most economical
process which involves less equipment. Because of this process is done by hand,
we can have a better control on the fiber orientation in the matrix material. The
molds can be made up of wood, sheet metal, plaster and FRP composites. The
Name: Zarnain khan Reg No: 20jzmec0388
Assignment01
molds are coated with gel to get the better surface quality. This is the oldest
commonly used manufacturing process.
Application:
Most of the aerospace composites are made by hand layup method.
This method is used to make polyester and epoxy resin parts such as boat hulls,
tanks and vessels.
>A gel coat is a resin usually 0.4 to 0.7 mm thick, commonly seen on the outer
surface of smaller boats
Name: Zarnain khan Reg No: 20jzmec0388
Assignment01
Spray-up Molding:
spray-up molding is much less labor intensive than the hand
layup method by utilizing a spray gun and a fiber cutter. However, only short fiber
reinforced composites can be made. A continuous fiber is fed into the cutter and
chopped. The chopped fiber is sprayed upon a mold with the stream of resin mist
and catalyst delivered through separate nozzles. The sprayed mixture of fiber and
resin soon cures on the mold at room temperature and the product is produced.
Because of the spraying operation, large and complex-shaped objects can be easily
made.
Fig.02 Spray-up molding
Application:
Applications include making of custom parts in low to medium
volume quantities. Bathtubs, swimming pools, boat hulls, storage tanks, duct and
air handling equipment, and furniture components are some of the commercial uses
of this process.
Fibers are chopped, coated with resin and sprayed onto the mold
Name: Zarnain khan Reg No: 20jzmec0388
Assignment01
Advantages:
Continuous process
Any materials can be used as mold.
Error can be corrected by re-spraying.
Disadvantages:
Slow.
Inconsistency.
No control of fiber orientation.
Only one side finished.
Environmental unfriendly.
Autoclave method:
Autoclave method is process of part molding by one of the
open molding methods in which the part is cured by a subsequent application of
vacuum, heat and inert gas pressure. The molded part is first placed into a plastic
bag, from which air is exhausted by a vacuum pump. This operation removes air
inclusions and volatile products from the molded parts. Then heat and inert gas
pressure are applied in the autoclave causing curing and densification of the
materials. Autoclave curing enables fabrication of consistent homogeneous
materials. The method is relatively expensive and is used for manufacturing high
quality aerospace products. An autoclave is a closed vessel in which processes
occur under simultaneous application of high temperature and pressure. This
process needs high pressure. Composites cure under heat and pressure provides a
superior part because the voids are reduced due to the pressure. The part is placed
in the pressure vessel, and heated, pressure is applied simultaneously.
Fig.03 Autoclave method
Name: Zarnain khan Reg No: 20jzmec0388
Assignment01
Application:
Vacuum bagging can be used in an autoclave. Thermoset composites
are cross linked and thermoplastics are melted. The pressure helps bond composite
layers, and removes more voids in matrix. Very large parts can be made. But it is
highly expensive.
Filament winding method:
It is a method which involves continuous filament
of reinforcement material wound around the mandrel in layers. It is used for
making round cylindrical parts. A tape of resin impregnated fibers is wrapped over
a rotating mandrel to form a part. These windings can be helical or hooped. Parts
vary in size from 1’’ to 20’. Winding speeds are typically taken as 100m/min. The
winding tensions are 0.1 to 0.5kg. High strengths are possible due to winding
designs in various directions. This process can be automated and provides high
production rate. High strength and different sizes of products can be made. It has a
control of strength in different directions. But complex shapes cannot be obtained.
The surface is poor.
Fig.04 Filament winding method
Name: Zarnain khan Reg No: 20jzmec0388
Assignment01
Application:
This method is used for making pressure vessels, storage tanks pipes. Also used to
produce rocket motors, launch tubes, drive shafts etc.
Winding process is defined with basic parameters for winding, like angle type,
number of cycles, cycle length, layers length, number of tows, etc.
Name: Zarnain khan Reg No: 20jzmec0388
Assignment01
Reaction molding method:
Two reactive ingredients are pumped at high
speeds and pressures into a mixing head and injected into a mold cavity where
curing and solidification occur due to chemical reaction. Stack of laminate consists
of fibers impregnated with sufficient thermoplastic matrix and polymer films of
complementary weight to give the desired fiber volume fraction in the end product.
These are then consolidated by simultaneous application of heat and pressure.
Generally, a pressure of 6 to 12 MPa, a temperature in between 2750C to 3500C
and dwell time of up to 30 minutes are appropriate for thermoplastics such as
polysulfones and polyetheretherketone.
Fig.05 Reaction molding method
Application:
Reaction Injection Molding is a low pressure, low temperature
process used to mold many types of plastic parts. This process is typically used
for the medical, industrial and automotive industries. Reaction Injection Molding
Name: Zarnain khan Reg No: 20jzmec0388
Assignment01
(RIM) is often utilized for the molding of strong, lightweight parts that are easily
painted.
CONCLUSION:
Polymer Matrix Composites are used in various industries
which is making design and development of PMCs more important. Apart from
introduction to the polymer matrix composite, in this Assignment i explain about
various techniques of making Polymer Matrix Composite. It reviews the
processing techniques of PMCs like Autoclave method, Filament Winding method
and Reaction injection molding method. It also provides the applications of the
processes used make various parts related to different industries.
Name: Zarnain khan Reg No: 20jzmec0388
