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Component Construction Defect

Belly fairing Aramid fibre sandwich Debonding due to soaking of Skydrol, oil and
construction moisture.
Radome Aramid fibre sandwich Debonding of inner/outer skin due to
construction aerodynamic loads and moisture. Damage to
honeycomb.
Air inlet cowl Inner barrel of carbon Wire mesh debonding, inner surface carbon
fibre reinforced sandwich fibre delamination. Damage to honeycomb.
construction covered with
stainless steel wire mesh
acoustic lining.
Trailing edge flap Aramid fibre sandwich Debonding due to heat effect as it is located in
fairings (rear of construction. the exhaust area.
engine)
Air conditioning duct Glass fibre reinforced Cracks and debonding.
composite.
Air inlet cowl aft Carbon fibre reinforced Debonding due to heat effect and vibrations.
bulkhead sandwich construction.
Horizontal stabilizer Carbon fibre reinforced Leading edge erosion. Erosion is arrested by
leading edge composite bonding stainless steel cap to the leading edge.
Passenger cabin Glass fibre reinforced Crushing and debonding.
floor boards sandwich construction.
Fin leading edge Carbon fibre reinforced Leading edge erosion. This is taken care by
composite. filling the affected area with epoxy and covering
the leading edge with anti- erosive tape.
Engine thrust reverse Carbon fibre reinforced Debonding of upper skin translating sleeve near
sandwich construction. double latch area due to excess load and heat
effect.
Engine thrust Aluminum face sheet Galvanic corrosion, debonding, heat damage.
reverser fixed bonded to aluminum
structure (C-Duct) honeycomb core.
Composite Applications
Coconut/jute/sisal fibre and gypsum plaster Boards for partitions, ceiling and wall
panel
Coconut/jute/sisal fibre and glass fibre with gypsum plaster Solid and perforated building blocks
Poplar wood with polymer Door shutters, doors and window
frames
Vegetable fibre/red mud and polyester Flat and corrugated roofing sheets,
shutters and tiles
Jute fibre polyester/epoxy with red mud Panels and sheets, wall cladding,
partitions and door shutters
Bagasse & UF/PF resin Panels and blocks
Coir fibre with fly ash & lime or cement Bricks & blocks for walling
Glass fibre reinforced polyester Roofing sheets, partitions, ceilings,
sanitary ware, water storage tanks,
pipes etc.
Glass fibre reinforced PP/nylon Door hinges
Red mud plastic (PVC, polyester) reinforced with sisal Paneling, roofing, partitions, door
fibre panels
Acrylic resin and quartz sand composite Kitchen sinks

Mechanical Properties Pultruded FRP Rigid Mild Stainless Wood


Polyester Vinyl PVC Steel Steel
Ester
2
Tensile Strength (N/mm ) 382 401 44 340 340 80
Flexural Strength 468 508 70 380 380 12
2
(N/mm )
Flexural Modulus 22489 48260 2400 196000 196000 700
2
(N/mm )
Izod Impact 1.36 1.63 0.09 1.5 0.53 ---
(Kg-m/cm)
Specific Gravity 1.80 1.80 1.38 7.8 7.92 0.52
Safe Working Temp. (° C) 120 170 55 600 600 160
Properties Pultruded Rigid Mild Stainless Wood
FRP PVC Steel Steel
Specific Gravity 1.8 1.38 7.8 7.92 0.52
Thermal Conductivity 24.4 6.4 1220 732.00 0.4
(Kcal/hr/m2/° C)
Coeff. of Linear Expansion 5.2 37 8 10 1.7
(cm/cm° C) x 10-6
Safe Working Temp. (° C) 130 55 600 600 160
Flame Resistance Good* Poor Excellent Excellent Poor
Corrosion Resistance
a. Acidic Excellent Good Poor Excellent Poor
b. Alkaline Good Fair Good Excellent Poor
c. Solvents Fair Poor Good Excellent Fair
d. Coastal Environment Excellent Good Poor Excellent Fair
e. Outdoor Exposure Excellent Poor Fair Excellent Fair
f. Effluent Water Excellent Good Poor Excellent Fair
g. Steam Good Poor Fair Excellent Fair

Excellent with special additives


Table M11.14: Physical & Chemical Properties of Pultruded Profiles Vs. Other Structural
Materials
Sl. Type of FRP Fan Flow Total Shaft FRP Fan Efficiency FRP Fan
No. Rate Pressuremm Power Efficiency Improvement Energy
M3/Sec. water gauge (kW) as over Savings over
Certified Conventional Conventional
by User Fan Fan
Agencies
1. Cooling Tower Fan+ 240.47 8.48 23.24 86.06% Superior Superior
2. Textile Mill 19.04 34.83 - 78.01% 24.58% Superior
Humidifier Fan *
3. Mine Ventilation 48.60 to 92.83 89.63 59.40% 8.22% 21.96%
Fan+ 81.00
4. Radiator Cooling Fan 49.76 to 88.56 to 74.95 65.67% to 2.33% to 1.86% to
for Railway Diesel 60.21 102.98 to 70.24% 9.62% 4.60%
Locomotives* 78.60
5. Air-heat Exchanger 91.43 to 8.26 to 8.56 10.1 to 74.01% to 20.79% to 28.96% to
Fan+ 96.94 10.17 80.04% 21.09% 34.93%

Table M11.19: Test Results of FRP Fans Vs. Conventional Metallic Fans
* Tested on the Test Rig as per ANSI/AMCA 210-85 + Tested on Site

Property Jute Banana Sisal Pine- Coir Cotton Glass


apple
Width or Diameter (mm) - 80-250 50-200 20-80 100-450 12-20 7-8
Density (gms./cc) 1.3 1.35 1.45 1.44 1.15 1.52 2.5
Volume Resistivity at 100 - 6.5-7 0.4-0.5 0.7-0.8 9-14 - 9-10
volts (W cm x 105)
Micro-Fibrillar Angle 8.1 11 10-22 14-18 30-49 20-23 -
(degree)
Cellulose/Lignin Content 61 /12 65 /5 67 /12 81 /12 43 /45 96/94 -
(%)
Elastic Modulus (GN/m2) - 8-20 9-16 34-82 4-6 27 85.5
Tenacity (MN/m2) 440-533 529-754 568-640 413- 131-175 267-345 4585
1627
Elongation (%) 1-1.2 1.0-3.5 3-7 0.8-1.6 15-40 3-10 5.7
Moisture Absorption after 6-9 - - - 12 7-8 0.5
24 h (%)
Aspect Ratio (L/D) (mm) 152-365 - - - - 500- 100-140
1300

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