CASE STUDY : MATERIALS FOR LAPTOP BODY ABS engineering plastic

Acrylonitrile butadiene styrene (chemical formula (C8H8)x (C4H6)y(C3H3N)z) is a common thermoplastic. Its melting point is approximately 105 C (221 F). It is a copolymer made by polymerizing styrene and acrylonitrile in the presence of polybutadiene. The proportions can vary from 15 to 35% acrylonitrile, 5 to 30% butadiene and 40 to 60% styrene. The result is a long chain of polybutadiene criss-crossed with shorter chains of poly (styrene-coacrylonitrile). The nitrile groups from neighbouring chains, being polar, attract each other and bind the chains together, making ABS stronger than pure polystyrene. The styrene gives the plastic a shiny, impervious surface. The butadiene, a rubbery substance, provides resilience even at low temperatures. It can also be recycled. ABS plastic is damaged by sunlight. The most important mechanical properties of ABS are impact resistance and toughness. A variety of modifications can be made to improve impact resistance, toughness, and heat resistance. The impact resistance can be amplified by increasing the proportions of polybutadiene in relation to styrene and also acrylonitrile, although this causes changes in other properties. Impact resistance does not fall off rapidly at lower temperatures. Stability under load is excellent with limited loads. Thus, changing the proportions of its components ABS can be prepared in different grades. Two major categories could be ABS for extrusion and ABS for injection moulding, then high and medium impact resistance. Generally ABS would have useful characteristics within a temperature range from -20 to 80 C (-4 to 176 F).

ABS's light weight and ability to be injection molded and extruded make it useful in manufacturing laptops. Its glass transition temperature makes it a material of choice for rapid prototyping. Relatively high as to reduce unwanted deformation at slightly elevated temperatures but low enough to be safely attainable with standard extrusion setups.

Carbon Fiber Material Carbon fiber, alternatively graphite fiber, carbon graphite or CF, is a material consisting of fibers about 510 m in diameter and composed mostly of carbon atoms. The carbon atoms are bonded together in crystals that are more or less aligned parallel to the long axis of the fiber. The crystal alignment gives the fiber high strength-to-volume ratio (makes it strong for its size). Several thousand carbon fibers are twisted together to form a yarn, which may be used by itself or woven into a fabric. The properties of carbon fibers, such as high flexibility, high tensile strength, low weight, high resistance, high temperature tolerance and low thermal expansion, make them very popular in aerospace, civil engineering, military, and motorsports, along with other competition sports. However, they are relatively expensive when compared to similar fibers, such as glass fibers or plastic fibers. Carbon fibers are usually combined with other materials to form a composite. When combined with a plastic resin and wound or moulded it forms carbon fiber reinforced plastic (often referred to also as carbon fiber) which is a very high strength-to-weight, extremely rigid, although somewhat brittle material. However, carbon fibers are also composed with other materials, such as with graphite to form carbon-carbon composites, which have a very high heat tolerance

The process by which most carbon-fiber-reinforced polymer is made varies, depending on the piece being created, the finish (outside gloss) required, and how many of this particular piece are going to be produced. In addition, The choice of matrix can have a profound effect on the properties of the finished composite.

Aluminium It is not soluble in water under normal circumstances. Aluminium is the third most abundant element (after oxygen and silicon), and the most abundant metal, in the Earth's crust. It makes up about 8% by weight of the Earth's solid surface. Aluminium metal is too reactive chemically to occur natively. Instead, it is found combined in over 270 different minerals. Aluminium is remarkable for the metal's low density and for its ability to resist corrosion due to the phenomenon of passivation. Aluminium is a soft, durable, lightweight, ductile and malleable metal with appearance ranging from silvery to dull gray, depending on the surface roughness. Aluminium has about one-third the density and stiffness of steel. It is easily machined, cast, drawn and extruded. Corrosion resistance can be excellent due to a thin surface layer of aluminium oxide that forms when the metal is exposed to air, effectively preventing further oxidation. The strongest aluminium alloys are less corrosion resistant due to galvanic reactions with alloyed copper. Aluminium is a good thermal and electrical conductor, having 59% the conductivity of copper, both thermal and electrical. Aluminium is capable of being a superconductor. Aluminium is theoretically 100% recyclable without any loss of its natural qualities.

 Magnesium and Magnesium Alloys

Magnesium is a fairly strong, silvery-white, light-weight metal (two thirds the density of aluminium). It tarnishes slightly when exposed to air, although unlike the alkali metals, storage in an oxygen-free environment is unnecessary because magnesium is protected by a thin layer of oxide that is fairly impermeable and difficult to remove. Magnesium reacts with water at room temperature, though it reacts much more slowly than calcium. Magnesium is a highly flammable metal, but while it is easy to ignite when powdered or shaved into thin strips, it is difficult to ignite in mass or bulk. On burning in air, magnesium produces a brilliant white light which includes strong ultraviolet. Later, magnesium ribbon was used in electrically ignited flash bulbs. Flame temperatures of magnesium and magnesium alloys can reach 3,100 C (3,370 K; 5,610 F) although flame height above the burning metal is usually less than 300 mm. The main application field of magnesium is electronic devices. Because of low weight, good mechanical and electrical properties, magnesium is widely used for manufacturing of mobile phones, laptops, computers, cameras, and other electronic components. Magnesium alloys are mixture of magnesium with other metals, often aluminium, zinc, manganese, silicon, copper, rare earths and zirconium. Magnesium is the lightest structural metal. Magnesium alloys have a hexagonal lattice structure, which affects the fundamental properties of these alloys. Plastic deformation of the hexagonal lattice is more complicated than in cubic latticed metals like aluminium, copper and steel. Therefore magnesium alloys are typically used in laptop bodies.

 Polycarbonate
Polycarbonates received their name because they are polymers containing carbonate groups (O(C=O)O). Most polycarbonates of commercial interest are derived from rigid monomers. A balance of useful features including temperature resistance, impact resistance and optical properties position polycarbonates between commodity plastics and engineering plastics Polycarbonates, are a particular group of thermoplastic polymers. They are easily worked, moulded, and thermoformed. Because of these properties, polycarbonates find many applications. Polycarbonate is a very durable material. Although it has high impactresistance, it has low scratch-resistance. Polycarbonate is stronger, usable in a wider temperature range but more expensive. This polymer is highly transparent to visible light and has better light transmission characteristics than many kinds of glass.

Polycarbonate has a glass transition temperature of about 150 C (302 F), so it softens gradually above this point and flows above about 300 C (572 F). Low molecular mass grades are easier to mold than higher grades, but their strength is lower as a result. The toughest grades have the highest molecular mass, but are much more difficult to process. Unlike most thermoplastics, polycarbonate can undergo large plastic deformations without cracking or breaking. As a result, it can be processed and formed at room temperature using sheet metal. This makes it valuable in prototyping applications where transparent or electrically non-conductive parts are needed, which cannot be made from sheet metal.

Polycarbonate honeycomb exhibits a unique cell structure. The core has 3 orientations vs. the 2 orientations common with other honeycomb, making its properties more uniform. Each cell has a tubular form and is inherently stable. It has excellent dielectric properties, good thermal and electric insulator. It is fire resistant, corrosion resistant, fungi resistant. Sandwich skins can be melted to core. It uses temperature below 200 F.