TE-671 TEXTILE COMPOSITES

ASSIGNMENT # 01 THERMOPLASTIC AND THERMOSET POLYMERS FOR TEXTILE COMPOSITES

SUBMITTED BY MUHAMMAD SAJID FAHEEM 10-NTU-6012

INTRODUCTION: Polymer Matrix Composites (PMCs):

Polymer Matrix Composites are materials that consist of polymer/resin (which forms a matrix) and a reinforcing dispersed phase (which is usually in fibrous form). Polymer Matrix Composites have popularity due to low cost and simple manufacturing methods. Polymer Matrix Composites have two main disadvantages, low thermal resistance and high coefficient of thermal expansion.

Types of Polymer Matrix Composites:

There are two main categories of Polymer matrix composites depending upon the nature of polymer: (1) Thermoplastic Polymer Matrix Composites (2) Thermosetting Polymer Matrix Composites

THEMOPLASTIC AND THERMOSETTING POLYMERS:

Polymers have two major types based on their behavior when exposed to heat: (1) Thermoplastic Polymers (2) Thermosetting Polymers

Characteristics of Thermoplastic Polymers:

Thermoplastic polymers are generally ductile and tougher than thermoset polymers. Thermoplastic polymers can be melted by heating and solidified by cooling, due to which they are capable to undergo repeated reshaping and reforming. The individual molecular chains in thermoplastic polymers do not cross-link and therefore these polymers are flexible and reformable. Thermoplastic polymers may be either in amorphous or semicrystalline form. Typically higher forming temperatures and pressures are required for manufacturing of thermoplastic polymers than comparable thermoset systems. In thermoplastic polymers, individual molecular chains have linear structure with no chemical linkage between them. These molecular chains are held together in place by weak intermolecular forces such as Vander Waals forces and hydrogen bonding. On application of heat and pressure, these intermolecular bonds in a solid thermoplastic polymer can be temporarily broken, and the molecular chains can be moved relative to each other to flow into new positions. On cooling, the molecular chains solidify in their new positions, restoring the weak intermolecular forces between them and resulting in a new solid shape. Thus, a thermoplastic polymer can be softened and melted on heating, and reshaped or reformed as many times as desired.

Types of Thermoplastic Polymers used for PMCs:

Applications of Thermoplastic Polymers in the form of PMCs:

Nylons (Nylon 6, Nylon 6.6) Thermoplastic Polyester (PET, PBT), Polycarbonate (PC), Polyacetals Polyamide-imide, Poly-ether ketone (PEEK), Polysulfone (PSUL), Polyphenylene sulfide (PPS), Polyether imide (PEI) Used for injection molded articles in the form of discontinuous fibers

Used for moderately high temperature applications in the form of continuous fibers

Thermosetting Polymers:
Thermoset materials cannot be remelted or reformed after when these materials are cured. During the curing process, these materials form three-dimensional molecular chains, which are known as cross-linkings. Due to these cross-linkings, the molecules are not flexible and cannot be remelted and reshaped. The greater the number of crosslinkings, the more rigid and thermally stable the material will be. Thermosets may soften to some extent at higher temperatures. Thermosets are brittle in nature and are generally used with some form of filler and reinforcement. Easy processability and better fiber impregnation can be achieved when thermosetting polymers are used because the liquid resin is used at room temperature for various processes. Thermosets offer greater dimensional stability, better rigidity, and higher electrical, chemical, and solvent resistance. In thermoset polymers, the molecular chains are chemically joined together by cross-linking, forming a rigid and three-dimensional network structure. Once these crosslinks are developed during the polymerization process/reaction (which is known as the curing reaction), the thermoset polymer cannot be softened or melted and reshaped by applying heat and pressure. But if there is lower the number of cross-linkings between the molecular chains then it is possible to soften them at higher temperatures. Thermoset materials are generally stronger than thermoplastic materials due 3-D network of molecular chains and also exhibit better performance at high-temperature up to the decomposition temperature of the material.

Types of Thermosetting Polymers used for PMCs:

Applications of Thermosetting Polymers in the form of PMCs:

Epoxies Polyester, Vinyl Esters Phenolics Polyimides, Polybenzimidazoles (PBD), Polyphenylquinoxatine (PPQ) Used in aerospace and aircraft applications Used in automotive, marine, chemical and electric applications Used in bulk molding compounds Used for high temperature aerospace applications (temperature range: 250-400C)

PROCESSING OF THERMOPLASTIC AND THERMOSETTING POLYMER FOR MANUFACTURING PMCS:

Following are the different polymer matrix manufacturing methods, which can be applied to both types of resins such as thermoplastic and thermosetting polymers, however different considerations must be taken into account for each.

Hand Lay-up:
The resin material is usually rolled into reinforcing fibers that are placed in the mold (after a release film and gel coat in some cases). Hand lay-up is commonly used in the US aircraft industry to produce PMC parts.

Spray Lay-up:
In spray lay-up the reinforcement fibers are first chopped and mixed with resin and then sprayed into the mold. In order to achieve the complete wetting of the fiber bundles a roller is used. Using this technique low specific strength structures are produced.

Manual Prepreg Lay-up:

The prepreg is cut into a large number of layers depending upon the mold. The pre-cut prepregs are then layered within the mold.

Automatic Prepreg Lay-up:

(Applicable to flat panels or parts with moderate curves.) A tape-laying machine lays the prepreg within the mold, automatically cut the prepreg when the mold edge is reached. This process is continued until the part is completed.

Compression Molding:
In this process uncured resin and reinforcing material are mixed together and then spread into the cavity of a matched mold. As the mold is closed then the pressure increases, which results in filling the mold and the part is formed. This method may be used with prepregs also.

Liquid Composite Molding (LCM):

Resin Transfer Molding (RTM), Structural Reaction Injection Molding (SRIM), and Injection Compression Molding are the different types of LCM. A reinforcing fiber preform is placed in the mold cavity and a polymeric resin is injected into the sealed mold. Then a curing reaction starts which results in the solidification of the part. The cured part is then removed from the mold. LCM is best suited for high production volumes to lower the cost because LCM has a very high, non-recurring tooling cost.

Vacuum- Assisted RTM:

The resin is injected into a mold containing the reinforcing fiber material. Then the atmospheric pressure is applied against an evacuated system.

Resin Film Infusion:

The resin film (which is usually preformed) is placed in the bottom of the mold. Then with the help of heat and pressure applications the viscosity of the resin film is decreased and as a result the resin film is spread through the preformed mold shape.

Expansion RTM:
In this technique the expansion of the material takes lace when heated is placed in the preform. The resin is infused and the mold is heated which results in the expansion of the core material and subsequently the resin is forced into the remaining parts of the preform.

Transfer Molding:
The mechanism is similar to compression molding but the preformed mold is closed when the resin material is injected into it.

Filament Winding:
In this process the spools carrying the fibers are mounted to a creel. The strands of fibers from each spool are combined together and pulled through a resin bath. The strands are then fully activated with an initiator or hardener and the excess resin is removed. Then these strands are passed through a drying device and wound on to mandrel, which results into a desired part. Filament winding is used more extensively to manufacture composites than all other lay-up methods combined.

Fiber Placement:
Similar to filament winding, but enables all axes of motion.

Pultrusion:
Similarly as in the process of filament winding the continuous reinforcing fibers are drawn from creels, formed into a general shape, and drawn through a resin bath. The wetted fibers are then shaped (according to the requirement) as they converge toward a heated die, where curing occurs. As the perform exit the die it passes through a pulling system, which provides the force that pulls the materials through the entire system. The pultruded part is then cut and trimmed to the desired size.

Thermoforming:
The matrices are used that can repeatedly be softened or melted on heating and hardened or solidified on cooling, and that can provide increased fracture toughness and higher hot-wet use temperatures (thermoplastics).