Thermosets fibre reinforcement

Abstract. This chapter is concerned with an in-depth examination of the adherend surface pretreatments used prior to structural adhesive bonding. It encompasses the various substrates encountered, particularly but not exclusively, in the aerospace industry. It compares and contrasts mechanical, chemical and electrochemical methods used for substrates comprising aluminium alloys, titanium, stainless steel, thermoplastic and thermoset fibre reinforced composites and non-metallic honeycomb. Scanning and transmission electron microscope techniques are used to analyse and characterise many of the pretreated surfaces so produced. 

The generic thermosets are the epoxies and the polyesters (both widely used as matrix materials for fibre-reinforced polymers) and the formaldehyde-based plastics (widely used for moulding and hard surfacing). Other formaldehyde plastics, which now replace bakelite, are ureaformaldehyde (used for electrical fittings) and melamine-formaldehyde (used for tableware). 

GRP Glass-fibre reinforced plastic based on a thermosetting resin ... 

Both thermoplastics and thermosets can reap the benefit of fibre reinforcement although they have developed in separate market sectors. This situation has arisen due to fundamental differences in the nature of the two classes of materials, both in terms of properties and processing characteristics. 

Nowadays the major thermosetting resins used in conjunction with glass fibre reinforcement are unsaturated polyester resins and to a lesser extent epoxy resins. The most important advantages which these materials can offer are that they do not liberate volatiles during cross-linking and they can be moulded using low pressures at room temperature. Table 3.1 shows typical properties of fibre reinforced epoxy. 

The methods used for manufacturing articles using fibre reinforced thermosets are almost as varied as the number of material variations that exist. They can, however, be divided into three main categories. These are manual, semiautomatic and automatic. 

Recycling of glass fibre-reinforced plastics is reviewed, with special emphasis on remelting of thermoplastic composites, mechanical recycling of thermoset composites, depolymerisation and dissolution of thermosets and thermoplastics, closed loop recycling of glass, and the use of glass as a mechanical compatibiliser. 32 refs. 

ISO 75-3 2004 Plastics - Determination of temperature of deflection under load - Part 3 High-strength thermosetting laminates and long-fibre-reinforced plastics... 

ISO 10122 1995 Reinforcement materials -Tubular braided sleeves - Basis for a specification ISO 10371 1993 Reinforcement materials - Braided tapes - Basis for a specification ISO 12215-1 2000 Small craft - Hull construction and scantlings - Part 1 Materials Thermosetting resins, glass-fibre reinforcement, reference laminate ISO 15100 2000 Plastics - Reinforcement fibres - Chopped strands - Determination of bulk density... 

Results are presented of experiments undertaken by Gaiker in the manufacture of sandwich panels containing foam cores based on PETP recycled by a solid state polyaddition process developed by M G Ricerche. Panels were produced with glass fibre-reinforced unsaturated polyester and epoxy resin skins, and allthermoplastic panels with PE, PP, PS and glass fibre-reinforced PETP skins were also produced. EVA hot melt adhesives and thermoset adhesives were evaluated in bonding glass fibre-reinforced PETP skins to the foam cores. Data are presented for the mechanical properties of the structures studied. 

Research on the pyrolysis of thermoset plastics is less common than thermoplastic pyrolysis research. Thermosets are most often used in composite materials which contain many different components, mainly fibre reinforcement, fillers and the thermoset or polymer, which is the matrix or continuous phase. There has been interest in the application of the technology of pyrolysis to recycle composite plastics [25, 26]. Product yields of gas, oil/wax and char are complicated and misleading because of the wide variety of formulations used in the production of the composite. For example, a high amount of filler and fibre reinforcement results in a high solid residue and inevitably a reduced gas and oiFwax yield. Similarly, in many cases, the polymeric resin is a mixture of different thermosets and thermoplastics and for real-world samples, the formulation is proprietary information. Table 11.4 shows the product yield for the pyrolysis of polyurethane, polyester, polyamide and polycarbonate in a fluidized-bed pyrolysis reactor [9]. 

The crosslinking reaction, which occurs in the production of thermosets, also provides good adhesion to other materials. Therefore, epoxy and polyester resin matrices are used for fibre-reinforced composites, amino resins are used for bonding chipboard, while phenolics are used for bonding fibres in brake pads, and sand for metal casting. These specialised products do not fit in well with the discussion of thermoplastic properties in this... 

Unsaturated polyesters are mainly used as the matrix for glass fibre reinforcement, (in glass fibre reinforced thermoset systems). These are most commonly used in the manufacture of small boats, chemical containers, tanks and repair kits for cars. 

In this respect, (thermoset) plastics composites with discontinuous fibre products are already mostly used in the car body applications, where polyester/E-glass is predominating (mostly because of polyesters, economy, ease of processability and reasonable mechanical properties provided), followed by use of phenolics (when fire retardance is required, in friction linings and engine compartments), and epoxies. Replacement by carbon or aramid fibre reinforcements can reduce body mass by 40% (compared to steel) and with more added strength, but the cost is unfavourable at the moment, as mentioned previously [12, 13]. 

If the filaments are not wound onto a mandrel but simply gathered into relatively large bundles and led slowly into a heated consolidation zone, emerging from a die partly or completely cured, the primitive essentials of pultrusion are present (Fig. 2.3(b)). This process began as the thermosetting resin equivalent of extrusion, that is, it was a continuous operation for manufacturing profiles, such as rod and channels. The method has been extended to fibre reinforced thermoplastics. 

The fundamentals of reinforced plastics have already been outlined in Chapters 1 and 2. They are basically a combination of two materials. There is a fibre reinforcement (normally glass) which is embedded in a resin. The applications discussed here have historically employed thermosetting resins. The fibre bears most of the mechanical load placed on the structure, while the resin is there essentially to protect the fibre from chemical attack. 

Fibre reinforced polymers (FRPs) are composed of a reinforcement material (glass, aramid or carbon fibres) surrounded and retained by a (thermoplastic or thermosetting) polymer matrix (unsaturated polyester, epoxy, vinyl ester, or polyurethane). FRPs were first used in the rehahiUtation of reinforced or pre-stressed concrete, but they have also been widely used in the reinforcement of timber structures. 

Fibre reinforced plastics. The most wide-spread reinforcement is glass fibre as roving, chopped strand mat, fabric, etc. The most usual matrix materials are unsaturated polyesters and epoxy resins as thermosets. In glass fibre reinforced thermoplastics (e. g. ABS, PA, PPO), the length of the glass fibres is 1 to 3 mm. Other reinforcing fibres are aramide, asbestos, boron, carbon, etc. 

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