061510 Fiber Reinforced Polymer Composites for Infrastructures Liang
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Transcript of 061510 Fiber Reinforced Polymer Composites for Infrastructures Liang
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NSRP Product Design and Materials Technology Panel MeetingJune 15 16, 2010, Pittsburgh, PA
Fiber Reinforced Polymer
Composites for Infrastructures
CONSTRUCTED FACILITIES CENTERCONSTRUCTED FACILITIES CENTER
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NSF Industry/University Collaborative Research Center
Center for Inte ration of Com osites intoInfrastructure (CICI)
West Vir inia Univ. Lead Universit
Rutgers Univ.North Carolina State Univ.
.
Industry Members 30+
To promote and advance composites for infrastructural
a lications
o Fundamental research
o Applied research
o
o
Education and training
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CICI
Vision:To accelerate the adoption of polymer composites into
-
cooperation
Focus: Innovation and mass-production of advanced
ol mer com osites in a cost effective manner Integration of composite members and subsystems
into infrastructure systems through rapid
Development and growth through industrial supportby targeting at the needs of composites industries aswe as construct on n ustr es
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Composite Application by EndUse/Market Percentage
3.6 billion lbs. of US fiberglass thermoset compositesshipments in 2007
Copyright 2008 American Composites Manufacturers Association
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FRP Infrastructure A lications
Decking for Navy and MarinaDecking for Navy and Marina
Highways & BridgesHighways & Bridges Rapid Housing and Green BuildingsRapid Housing and Green Buildings
t ty o est ty o es
PipesPipes n ur ne a esn ur ne a es
Blast Resistant StructuresBlast Resistant Structures
Rail Road TiesRail Road Ties
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ONR Grant No. N00014-04/05-1-0050/96
Dr. Ignacio Perez, Program Officer
OBJECTIVE
To demonstrate feasibility of an automated pultrusion
process for producing composite sandwich panels (4x 3.5 x unlimited len th which results in a roductwith improved mechanical performance and reducedproduction cost in relation to VARTM process
Target panel: 1/4 FRP face sheets with 3 balsa core
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Vacuum-Assisted Resin Transfer Molding (VARTM)
Seeman's Composite Resin Injection Molding Process (SCRIMP)
Hybrid of VARTM and vacuum bagging
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MILESTONES OF THE PROJECT
20042004 1 sandwich panel (March 3, 2004), 300 sq ft1 sandwich panel (March 3, 2004), 300 sq ft 3.5 sandwich panel (May 18, 2004), 220 sq ft3.5 sandwich panel (May 18, 2004), 220 sq ft
Each 200 sq ft, total 400 sq ft,Each 200 sq ft, total 400 sq ft, No jointNo joint 2004 NSWC2004 NSWC--VARTM panel (Aug 25, 2004)VARTM panel (Aug 25, 2004)
1.25 sandwich panel for bond improvement (Oct 12, 2004, 40 sq ft)1.25 sandwich panel for bond improvement (Oct 12, 2004, 40 sq ft)Note: Better properties thru pultrusionNote: Better properties thru pultrusion
20052005
..
Two 400 sq ft runs (Jan 26 and June 28, 2005, total 800 sq ft)Two 400 sq ft runs (Jan 26 and June 28, 2005, total 800 sq ft) 2005 VARTM panel (May 31, 2005)2005 VARTM panel (May 31, 2005)
Joint evaluation under bending and shear,Joint evaluation under bending and shear, 100% joint efficiency100% joint efficiency20062006
3.5 carbon/vinyl ester sandwich panels3.5 carbon/vinyl ester sandwich panels
Two runs, 300 sq ft (June 23 and Sept 19, 2006))Two runs, 300 sq ft (June 23 and Sept 19, 2006)) FE analysesFE analyses
Orthotropic 3D Model, fully describing the panels static responsesOrthotropic 3D Model, fully describing the panels static responses
Carbon/vinyl ester vs. carbon/epoxyCarbon/vinyl ester vs. carbon/epoxy
3.5 glass/vinyl ester sandwich panels3.5 glass/vinyl ester sandwich panels High Temp Infusion ProcessHigh Temp Infusion Process
80 sq ft (Sept 19, 2007))80 sq ft (Sept 19, 2007)) FE analysesFE analyses
Full scale panel modeling, joint modelingFull scale panel modeling, joint modeling
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PULTRUSION OF GFRP PANEL -2005
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TESTING OF FRP LAMINATES
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SEM MICROGRAPHS OF FIBER/RESIN INTERFACE
Pultruded VARTM
Pultruded
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CFRP Failed Specimens Under Bending
Carbon /VE vs. Carbon/Epoxy
The high performance of carbon fiber has not translated into a proportionate
property improvement of CFRP composites over GFRP, due to the carbon sizing
incom atible with VE. Carbon/e ox should be recommended.
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Finite Element Modeling of FRP
A VARTM Joint
Deflection contours by 3D orthotropic solid model for 40x100 CFRP panel
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CONCLUSIONS Glass/VE
- Pultruded panel is ~15-20% stronger and stiffer, and 50%
- HT infused panel performs as well as VARTM panel, butcosts a third of VARTM panel
- o n e c ency
Carbon/VE- u tru e pane s ~ - st er, - stronger
and 15-20 % lighter than pultruded GFRP panel
- CFRP property improvement over GFRP not
commensurate to cost increase (Carbon ~$15 /lb fiber, $30/lb fabric vs. Glass ~$0.70/lb, $1.5-2.0/lb fabric)
- Carbon/epoxy is strongly recommended, due tocompatibility and durability issues with carbon/VE
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CONCLUSIONS (contd)
Pultrusion process
- Viable and cost effective than VARTM- g qua y pane
High Temp Resin Infusion
- Large size, flat, glass/VE or carbon/epoxy panel
- Viable and even more cost effective than pultrusion
Finite element modeling of panel response- 3D orthotropic solid model (3D geometry + orthotropic
material properties)
- Viable for accurate predictions of deflection, bending stress,and shear stress
- ~100% match between predictions and experimental data
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NSRP Project: Development of
for Low Cost Pultruded Composites
activities at the March 10 11, 2010 Panel Meeting at Biloxi, MS.
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Cost Improvement via Pultrusion or Infusion
DeckDeck
typetype
WeightWeightper unitper unit
CostCostper unitper unit
Cost perCost perunitunit
FailureFailurestressstress
lbs/sq ftlbs/sq ft $/sq ft$/sq ft $/lb$/lb
ksiksi
1# FRP1# FRP 2222 ~80~80 3.643.64 10101. Double trapezoid
2# FRP2# FRP
20002000
1919 ~58~58 3.053.05 3030
~~
20022002
..
4# FRP4# FRP
20032003
1010 ~25~25 2.52.5 3535--4040
2. Revisedtrapezoidal deck
CurrentCurrentFRP *FRP *
1818--2424 6565--100100 3.63.6--55 2525--3030
ConcreteConcrete 9090--120120 ~30~30 0.290.29--0.350.35 44--6 (C)*6 (C)*
3. Lightweightcomposite bridge
< 1 (T)< 1 (T)
4. Low profile bridge deck* Currently used FRP decks.
C: Compression T: Tension
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Highways & Bridges
Market Street Bridge Wheeling, WV
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Highways & Bridges
Goat Farm Bridge, Wirt County, WV
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Highways & Bridges
Pleasant Plain Road Brid e
Montgomery County, Ohio
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Highways & Bridges
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Highways & Bridges
FRP Inspection Walkway
Blennerhassett Brid e
Parkersburg, WV
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Hi hwa s & Brid es
FRP Wraps for rehabilitation
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Highways & Bridges
After
Before
FRP Wraps for rehabilitation
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Highways & Bridges
FRP Rebar, WV Route 9, Martinsburg, WV
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Hi hw Bri
Close-up of instrumented FRPowe ars
FRP dowels, Elkins, WV
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FRP Pavement Panel
Central I-beam (112 ft. long)
View at Section AAA A
I-Beams onright side(12ft. 6 inches)
I-Beams onleft side(12ft. 6
8.7 ft
8.7 ft
inches)
Edge I-beam flangesmay be trimmed toobtain C-shapedchannel
13 ft
8.7ft
13 ft 13 ft
Direction of hollow core cells
Figure 2: Panel layout and connections
New University High School
Morgantown, WV
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Field Implementation of
FRP Pavement Panels
A section of Bakers Ridge Road near University High School,Morgantown, West Virginia was the first to field-evaluate glass
(July 2009, Sponsored by WVDOH)
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Retainin Walls
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FRP Building
CFC-WVU designed, manufactured, and constructed thefirst FRP modular building in 1995 in collaboration with
WV DOT (photos taken on Aug 27, 2009)
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FRP composite home being erected at BRP
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Utility Poles $4 billion treated wood$4 billion treated wood
poles annually in USpoles annually in US
Photo courtesy of Hiel, 2001
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Pipelines
Each year, ~1000 miles newnatural gas pipelines go intoserv ce eac year w e ~
miles is replaced
,gas transmission pipelines arebeing built in the 2001-2010
timeframe at a cost of over $80billion in North America
O Th l E C i (OTEC)
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Ocean Thermal Energy Conversion (OTEC)
OTEC exploits existing ocean temperaturegradients to drive a heat engine
78F
72Fene ts:
Large Renewable Energy Source
3-5 Terawatts available*
Base Load Power 24/7
ColdWaterPip
Closed Cycle OTEC System
Secure source, independent of oil imports Near-carbon free
Fresh Water Production
e
Credit : Lockheed Martin Co
6/16/2010 35
* A Preliminary Assessment of OTEC Resources ASME 3/2007
OTEC is a renewable energy source for DOD bases and over 80 countries
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Ocean Thermal Energy Conversion Cold Water Pipe
J LJ L
J L Ruhle & Associates
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Pipeline Infrastructure in US
FRP TanksPhoto Courtesy of FRPglasstankandpipe.com
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Composite Turbine Blades for Wind Energy
Global market for wind
2020
Photo courtesy of Wikipedia
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Composite Turbine Blades for Wind Energy
o e ero yn185 blade identifying
axial strains
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Fire Protection of Structures
Fire testing of a FRP composite
panel
Panel withstood 5800 degree F
Acetylene torch for 5 minutes
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himn Fl FRP composites are used in smoke stacks for
Large diameter FRP structures are needed
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Chimneys/Flues
Elbow) (courtesy ofInternational Chimney)
Stack Liner Installation in a
Power Plant (Kelley, 2007)
Engineered Recycled Thermoplastic
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Engineered Recycled Thermoplastic
Composites
Offset Blocks Made of Rec cled Plastic
Recycled Polymer Composite Shell and Used Wood Tie as a Core
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Summary
WVUWVU--CFC has been extensively researching and developingCFC has been extensively researching and developing
FRP com osite materials and s stems for infrastructure andFRP com osite materials and s stems for infrastructure and
military applications for over 20 years.military applications for over 20 years. Many of these systemsMany of these systems
have already been field implemented and are performinghave already been field implemented and are performing
outstandinglyoutstandingly
The CFCThe CFC--WVU team has made major strides in advancing theWVU team has made major strides in advancing the
s a es a e--oo -- ee--ar o compos e sc ences an ec no og esar o compos e sc ences an ec no og es
through integration ofthrough integration of
new fabric architecturesnew fabric architectures
modified resin systemsmodified resin systems innovative processing methodsinnovative processing methods
a wide range of mechanical and chemical (adhesive)a wide range of mechanical and chemical (adhesive)
joining mechanismsjoining mechanisms
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Summary (Contd)
CFCCFC--WVU will continue to work closely with a range ofWVU will continue to work closely with a range of
boundaries of composite applications and expand theboundaries of composite applications and expand thesuccess of fieldsuccess of field--implementing economical and durableimplementing economical and durable
FRP composite structural systems, including naturalFRP composite structural systems, including natural
fiber composites for green buildings.fiber composites for green buildings.
CFCCFC--WVU is currently leading a NSF sponsoredWVU is currently leading a NSF sponsored
Industry/University Collaborative Research Center forIndustry/University Collaborative Research Center for
.. --
industry Consortium will help pave the path toindustry Consortium will help pave the path to
accom lish the above mission.accom lish the above mission.