Reinforced plastics costs

Thermosetting unsaturated polyester resins constitute the most common fiber-reinforced composite matrix today. According to the Committee on Resin Statistics of the Society of Plastics Industry (SPl), 454,000 t of unsaturated polyester were used in fiber-reinforced plastics in 1990. These materials are popular because of thek low price, ease of use, and excellent mechanical and chemical resistance properties. Over 227 t of phenoHc resins were used in fiber-reinforced plastics in 1990 (1 3). PhenoHc resins (qv) are used when thek inherent flame retardance, high temperature resistance, or low cost overcome the problems of processing difficulties and lower mechanical properties. 

FIG. 10-184 Cost of shop-fabricated tanks in mid-1980 with V4-in walls. Multiplying factors on carbon steel costs for other materials are carbon steel, 1.0 mbber-lined carbon steel, 1.5 alnminnm, 1.6 glass-lined carbon steel, 4.5 and fiber-reinforced plastic, 0.75 to 1.5. Multiplying factors on type 316 stainless-steel costs for other materials are 316 stainless steel, 1.0 Monel, 2.0 Inconel, 2.0 nickel, 2.0 titanium, 3.2 and Hastelloy C, 3.8. Multiplying factors for wall thicknesses different from V4 in are ... 

A wide variety of thermoplastics have been used as the base for reinforced plastics. These include polypropylene, nylon, styrene-based materials, thermoplastic polyesters, acetal, polycarbonate, polysulphone, etc. The choice of a reinforced thermoplastic depends on a wide range of factors which includes the nature of the application, the service environment and costs. In many cases conventional thermoplastic processing techniques can be used to produce moulded articles (see Chapter 4). Some typical properties of fibre reinforced nylon are given in Table 3.2. 

The purchased cost,, of the absorption column (fiberglass reinforced plastic shell and auxiliaries excluding packing) is given by (Vatavuk, 1995) ... 

The term reinforced plastic (RP), also called composites (more accurately plastic composites), refers to combinations of plastic (matrix) and reinforcing materials that predominantly come in fiber forms such as chopped, continuous, woven and nonwoven fabrics, etc. also in other forms such as powder, flake, etc. They provide significant oriented property and/or cost improvements than the individual components (10, 14, 35, 38, 39-43, 62). 

Conventional machining operations are used preferably from the same plastic to be used in the product (Chapter 8, SECONDARY EQUIPMENT). Different casting techniques are used that provide low cost even though they are usually labor intensive. The casting of unfilled or filled/reinforced plastic used include TS polyurethane, epoxy, structural foam, and RTV silicone. Also used are die cast metals. 

Glass Melt blowing and spinning High strength Low modulus Low temperature Low cost Insulation Reinforced plastics... 

Carbon Pyrolysis High strength High modulus Low density Low oxidation resistance Medium cost Reinforced plastics Carbon-carbon High-temp insulation... 

Baines, D. (1984) Chem. Engr., London No. 161 (July) 24. Glass reinforced plastics in the process industries. Bendall, K. and Guha, P. (1990) Process Industry Journal (Mar.) 31. Balancing the cost of corrosion resistance. 

Domier has developed a production route for continuous fiber-reinforced ceramics based on the impregnation and pyrolysis of Si-polymers. This process is related to the manufacturing of fiber-reinforced plastics and allows the cost-effective production of large and complex CMC-structures. 

Fiber reinforced ceramics such as C/SiC, SiC/SiC can be manufactured by the polymer infiltration and pyrolysis technique at reasonable cost. The developed production technique allows the manufacturing of large and complex structures comparable to fiber-reinforced plastics. The material has excellent high temperature resistance, low density, and good damage tolerance, and is therefore well... 

The effects of amendments to the Environmental Protection Act (1990), which relate to pollution control and styrene emissions from installations, on UK fibre reinforced plastics processors are examined. Possible cost-effective abatement solutions are briefly considered. 

Choosing a reinforced plastic or one from a more-sophisticated polymer family to provide higher performance can be used to cut overall costs by reducing wall thickness and thus reducing material weight and material cost and enhancing the processing. 

Reinforced plastics differ from high-pressure laminates in that little or no pressure is employed. For instance, in making formed shapes, impregnated reinforcing material is cut to a desired shape, the various layers are added to a mold, which is then heated. This process is favored over the high-pressure process because of the use of a simpler, lower cost mold and production of strain-free products. 

Reinforced plastics may also include fillers (qv), which are inexpensive materials such as calcium carbonate used to displace resin and reduce cost curing agents (catalysts), promoters, inhibitors, and accelerators, which affect thermosetting resin cure colorants release agents (qv) to facilitate removal from the mold and other additives which can impart a wide variety of properties to the finished part, such as fire resistance, electrical conductivity, static dissipation, and ultraviolet resistance. 

There are no simple rules of thumb in defining the cost of reinforced plastic components. Their successful use has resulted from proper design, utilizing the benefits these materials offer, process selection, tooling cost advantages that fit the production needs, and consideration of life cycle economics. Each existing application illustrates the cost-performance advantage of reinforced plastic over the traditional material that is displaced. 

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