Reinforcement and composite

Guides to Pollution Prevention The Fiberglass-Reinforced and Composite Plastics Industry... 

Macroscale reinforcements and composites have thus far received the most investigation and application. The remarkable advances in the development of these polymeric matrices composites in the twentieth century have made these materials prominent, which is expected to continue despite advances in smaller-scale, mainly nanometric, reinforcements. 

Due to rapid changes in the cost and availability of conventional construction materials used for marine structures, and the development (or increasing acceptance of) newer materials such as stainless steel for concrete reinforcement and composite materials, the economic balance reflected by conventional practice often is no longer valid. The challenge is to realistically evaluate alternative systems in terms of performance and cost so that new construction and the maintenance and repair of existing structures can be accomplished in a manner that adequate service is obtained at the lowest life-cycle cost. 

The variety of combinations available in epoxies and reinforcements provides wide latitude in the properties of fabricated parts. Some fiber-reinforced and composite materials can withstand service temperatures even above 260 C (SOOT) for brief periods. Their excellent electrical and mechanical performance qualifies them for use in many electro-structural parts. 

The results presented below were obtained using a 2 mm thick carbon fiber reinforced epoxy composite laminate with 16 layers. The laminate was quasi isotropic with fiber orientations 0°, 90° and 45°. The laminate had an average porosity content of approximately 1.7%. The object was divided in a training area and an evaluation area. The model parameters were determined by data solely from the training area. Both ultrasound tranducers used in the experiment had a center frequency of 21 MHz and a 6 dB bandwidth of 70%. 

Hot pressing produces compacts that have superior properties, mainly because of higher density and finer grain size. Closer dimensional tolerances than can be obtained with pressing at room temperature are also possible. Hot pressing is used only where the higher cost can be justified. It has been usehil in producing reactive materials. One use is the combination of P/M and composites to produce hot-pressed parts that are fiber reinforced. 

The interface region in a composite is important in determining the ultimate properties of the composite. At the interface a discontinuity occurs in one or more material parameters such as elastic moduli, thermodynamic parameters such as chemical potential, and the coefficient of thermal expansion. The importance of the interface region in composites stems from two main reasons the interface occupies a large area in composites, and in general, the reinforcement and the matrix form a system that is not in thermodynamic equiUbhum. 

Thermal expansion mismatch between the reinforcement and the matrix is an important consideration. Thermal mismatch is something that is difficult to avoid ia any composite, however, the overall thermal expansion characteristics of a composite can be controlled by controlling the proportion of reinforcement and matrix and the distribution of the reinforcement ia the matrix. Many models have been proposed to predict the coefficients of thermal expansion of composites, determine these coefficients experimentally, and analy2e the general thermal expansion characteristics of metal-matrix composites (29-33). 

Fig. 14. Reinforcement and crack tip kiteractions ki a particulate composite (a) coarse particles ki a strong particle—matrix kiterface, and (b) fine particles ki...

Electronic-Grade MMCs. Metal-matrix composites can be tailored to have optimal thermal and physical properties to meet requirements of electronic packaging systems, eg, cotes, substrates, carriers, and housings. A controUed thermal expansion space tmss, ie, one having a high precision dimensional tolerance in space environment, was developed from a carbon fiber (pitch-based)/Al composite. Continuous boron fiber-reinforced aluminum composites made by diffusion bonding have been used as heat sinks in chip carrier multilayer boards. 

Flammability. PhenoHcs have inherently low flammabiHty and relatively low smoke generation. For this reason they are widely used in mass transit, tiinnel-building, and mining. Fiber glass-reinforced phenoHc composites are capable of attaining the 1990 U.S. Federal Aviation Administration (FAA) regulations for total heat release and peak heat release for aircraft interior facings (1,70). 

Composites. High molecular weight PPS can be combiaed with long (0.6 cm to continuous) fiber to produce advanced composite materials (131). Such materials having PPS as the polymer matrix have been developed by usiag a variety of reinforcements, including glass, carbon, and Kevlar fibers as mat, fabric, and unidirectional reinforcements. Thermoplastic composites based on PPS have found application ia the aircraft, aerospace, automotive, appliance, and recreation markets (see Composite materials, polymer-matrix). 

It is important to note that reinforced plastics remain a combination of materials differing in form or composition on a macro scale. The main constituents (resin, reinforcement, and filler) retain their identities and do not dissolve or merge into each other rather, they act in concert. These components can be physically identified and exhibit an interface between each other. 

AH forms and compositions of reinforcements, ie, mats, woven roving, glass, carbon, and aramid, are commonly used with these processes. Special continuous glass strand mats with a thermoplastic binder aHow preforms to be made using thermoforming techniques. These processes are used for tmck and autobody components, medical equipment cabinets, transportation seating, and other parts needed in the intermediate volume range (1,000—10,000 parts/yr). 

S. J. Monte and G. Sugerman, Proceedingsfrom the 33rd Technology Conference, Reinforced Plastics/Composite Institute, Washington, D.C., 1978. 

M. Borowc2ak and A. G. Causa, "Eatigue Behaviour of Cord-Reinforced Rubber Composites," Conference Proceedings ACS, RubberDivision, Louisville, Ky., May 1989. 

W. W. Blount and co-workers, SFI Reinforced Flastics Composites Institute, Froceedings 27th Annual Conference, Eeb. 8—11, Society of the Plastic Industry, New York, 1972, Pt. 12-C. 

Fig. 3. Tensile stress—strain curve for (-) reinforced ceramic and ( " ) fiber-reinforced ceramic composite. A represents the point where the matrix...

Applications. Epoxy resias constitute over 90% of the matrix resia material used ia advanced composites. In addition, epoxy resias are used ia all the various fabrication processes that convert resias and reinforcements iato composite articles. Liquid resias ia combiaation, mainly, with amines and anhydride are used for filament winding, resia transfer mol ding, and pultmsion. Parts for aircraft, rocket cases, pipes, rods, tennis rackets, ski poles, golf club shafts, and fishing poles are made by one of these processes with an epoxy resia system. 

A partial answer to the first question has been provided by a theoretical treatment (1,2) that examines the conditions under which a matrix crack will deflect along the iaterface betweea the matrix and the reinforcement. This fracture—mechanics analysis links the condition for crack deflection to both the relative fracture resistance of the iaterface and the bridge and to the relative elastic mismatch between the reinforcement and the matrix. The calculations iadicate that, for any elastic mismatch, iaterface failure will occur whea the fracture resistance of the bridge is at least four times greater than that of the iaterface. For specific degrees of elastic mismatch, this coaditioa can be a conservative lower estimate. This condition provides a guide for iaterfacial desiga of ceramic matrix composites. 

Another consideration is the difference in thermal expansion between the matrix and the reinforcement. Composites are usually manufactured at high temperatures. On cooling any mismatch in the thermal expansion between the reinforcement and the matrix results in residual mismatch stresses in the composite. These stresses can be either beneficial or detrimental if they are tensile, they can aid debonding of the interface if they are compressive, they can retard debonding, which can then lead to bridge failure (25). 

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