PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar …2014.pdf · 2014. 3. 12. · POLYMER...
Transcript of PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar …2014.pdf · 2014. 3. 12. · POLYMER...
PROPERTIES OFPOLYMER COMPOSITE MATERIALS
Prof. Zaffar Mohammad Khan, PhD.
From Dedaulus to Vvyln
EVOLUTION OF COMPOSITES
COMPOSITES IN BARJ UL ARAB
COMPOSITE GROWTH RATE IN ENGINEERING INDUSTRIES
THE ALL COMPOSITE WORLD
Any modern economy is built on the ability to exploit the opportunities onoffer by new and existing high value markets – such as composites
Lord Mandelson
What are Composite Materials???
Composite materials aremacroscopic combination oftwo or more materialscomplimenting each othersuch that resulting producthas superior properties:
1.Matrix (Black)2.Reinforcement Fibers (White)3.Inter-phase
STRONGER THAN STEEL YET LIGHTER THAN
ALUMINIUM
Matrix Constituent
Roles:
• Binds and holds reinforcement together
• Determines composite shape and geometry
• Transfers stresses to reinforcement
Types:
• Ceramic (Temp < 6000°F)• Metallic (Temp < 4000°F)• Polymeric (Temp < 600°F)
Determine
• Environmental resistance• Shelf Life• Compressive & transverse
mechanical properties of composite
Examples:• Epoxy, Polyester, Vinyl
ester, PEEK, Polycarbones
Reinforcement Constituent1. Particulate: Good compression
strength but poor tensile properties, and particles in cement.
2. Flakes: Effective solvent resistant but difficult fabrication.
3. Whiskers: High degree of strength but poor crack stopping properties.
4. Fibers: Better structural properties, crack stopping properties, flexibility of design requirement by changing orientation of fibers 0°, +45°, 90°Stacking sequence
Examples: glass, carbon, kevlar & carbon fibers
Fiber Architecture
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ADVANTAGES OF COMPOSITE MATERIALS
• Significant weight saving which increases payload and/or range along with fuel saving.
• Maximum specific strength and stiffness make them lighter than aluminum, stronger than steel.
• Permits aero-elastic tailoring of structural components.
• Flexibility of Design• Integrated structures diminishes
application of rivets.• Enhanced fatigue life.• Absence of corrosion.
Reduced operational,manufacturing
and maintenance cost.
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Comparison of Composites with Metals
Aero-elastic Composite Structure
• Permits aero-elastic tailoring of structural components.
• The composite structure is tailored to meet varying aerodynamic requirements in aircrafts, cars and wind rotor blades. It reduces drag and enhances energy conservation.
Flexibility of Composite Design
• The mechanical properties of the composite structures could be optimized for tensile, shear or compression loadings through proper selection of fiber types, orientation and stacking sequence
Integrated Structure
• Integrated composite structure reduces rivets and associated weight which leads to integrated structure.
• Reduce operational, manufacturing and maintenance cost.
The vibration damping characteristics of composites are far superior as compared to metals for following reasons;
1.Matrix visco-elastic effects andmicro-cracking
2.Blunting of crack by in fiberstransverse direction
3.Debonding and sliding of fibersin axial direction.
Influence of Vibrations on Composites
Manufacturing Methods and typical Applications• Hand Lay-up Method: Ships, wind
turbine blades, reinforcement to concrete bridge columns and slabs.
• Autoclave Method: Aircraft, space equipment, racing car
• Pultrusion Method: Rod, pipe• Filament Winding Method: Rolls,
pressure vessels, fly wheels, centrifugal separation
• Resin Injection Method: Aircraft components
• Prepreg Sheet Winding Method:Golf shaft, fishing rod
• Pressure Matched-Metal Die Method: Tennis racket, badminton racket
• Injection Method: General equipment
Autoclave Manufacturing
Structural Analysis
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Cost & WeightConsideration
GeometricalEnvelop
ManufacturingProcesses
LoadingSpectra
Conceptual DesignA creative function providing an Initial set of design drawings
Inspection
CandidateMaterialsEnvironment
Trade Off StudiesCost/Weight Considerations
ModifyConcept
Acceptable Preliminary DesignDefines materials and structural configuration,Manufacturing and tool plans, initial costs
Detail Design & EvaluationDesign and analysis of complete structure,Local details, design-to-cost evaluation, QA plans
DevelopmentAnd Testing
ModifyDesign
Production PhaseUpdating cost/weight trade studies,Manufacturing Plans, tooling etc.
Acceptable Detail Design
PrototypeManufacture
Modify(if required)
COMPOSITE DESIGN
Aircraft and Automobiles
Composite Structures
Composites in Skiing and Cycling
Medical Industry
• The composite prosthesis is beneficial for people having physical disabilities.
• Applications include leg and foot prosthetics providing weight reduction of up to 68% compared to traditional metals such as stainless steel.
All Composite Car Body by Liquid Resin Infusion(Joint Venture of Academia-Industry Collaboration)
• Structural design and analysis using the Pro-E and ANSYS tools
• The pattern and mold was manufactured from carbon and glass /polyester composites.
• Resin impregnation through carbon fabric and curing using Resin Infusion Process.
• The car took part in Shell Eco Marathon Race in Malaysia and secured 26/ 120 position.
• Published in 42nd SAMPE Technical Conference Proceedings, Utah, USA [2].
• http://www.sampe.org/store/paper.aspx?pid=6280.
Development of Windmill Turbine BladesResearch Initiative by Academia, Industry & Research Center
• Wind Speed: 5-7 m/ sec.• Air Density: 1.25 Kg/ m3• No of blades: 3• NACA Profile: 4527.• Rotor Blade Diameter: 2.21 m• Hub Height: 6’-10”
• Design and Analysis at NUST. • Vacuum bagging over mold
having geometry at FiberTech.• Structural testing at ACRC.
SR NO
Maximum Load (KG)
Bending StiffnessKN/M
Bending Stiffness
Downward(KN/M)
Bending Stiffness Average(KN/M)
Applied load
UpwardKN
Applied load
DownwardKN
Maximum Displacement
Upwardmm
Maximum Displacement
Downwardmm
1 10 19.45 11.85 15.65 0.14 0.10 8.25 8.252 20 18.64 12.66 15.65 0.26 0.21 15.03 14.103 30 15.30 11.21 13.25 0.34 0.29 21.17 21.17
Effect of Voids on Mechanical Properties of Carbon Epoxy Composite Materials
• Carbon-epoxy specimen were prepared by vacuum bagging, VARTM and RFI.
• Specimen were tested in tension, shear and flexural loading according to ASTM and correlated with degree of porosity.
• Porosities were observed in the test specimen and correlated to mechanical properties.
1001.7
1879.86
0
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
TVBU TVIU
Stre
ss (M
Pa)
TVBU TVIU
582.76
1059.05
0.00
200.00
400.00
600.00
800.00
1000.00
1200.00
FVBU FVIU
Stre
ss(M
Pa)
FVBU FVIU
Effect of Post cure on Mechanical Properties of Sandwich Composites
• The polystyrene foam, honeycomb, balsa wood cored sandwich having carbon fabric face sheets were cured/ post cured. • Edgewise, flexural tests were conducted according to ASTM C364 & C393. • Honeycomb structure demonstrated superior edgewise compression strength as compared to Styrofoam and Balsa wood. • Post curing improved the compression strength of sandwich structure
Edgewise Compressive stress of Styrofoam core sandwich structures
0.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
16.00
18.00
SF without Post cure SF with Post cure
Edge
wis
eco
mpr
essi
vest
ress
(MPa
)
Edgewise compressive strength of Honeycomb Core sandwich structures
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
HC without Post cure HC with Post cure
Edge
wis
e C
ompr
essi
ve s
tres
s(M
Pa)
Tg Comparison Chart
0
10
20
30
40
50
60
70
80
90
Poly Epoxy without PC Poly Epoxy with PC
Tem
pera
ture
(C)
CONCLUSION
• Processing of composite materials may be taught. Campuses and R&D Center should be established to promote, composite science and technology.
• Advanced Composite promise to save upon energy needs in mass transportation by 5% and accelerated socio-economic development of engineering industries.
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THANK YOU