Application of Fiber Composites

A composite material is made by combining two or more materials to give a unique combination of properties, one of which is made up of stiff, long fibres, and the other, a binder or 'matrix' which holds the fibres in place. The fibres are strong and stiff relative to the matrix and are generally orthotropic. Composites are a versatile and valuable family of materials that can solve problems of different applications, improve productivity, lower cost and facilitate the introduction of new properties in materials.

Synthetic Fiber Composites:

Carbon Fiber
Carbon fiber is a material consisting of extremely thin fibers about 0.0050.010 mm in diameter and composed mostly of carbon atoms. The carbon atoms are bonded together in microscopic crystals that are more or less aligned parallel to the long axis of the fiber. The crystal alignment makes the fiber very 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 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 for example 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 molded 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. Carbon fiber is most notably used to reinforce composite materials Non-polymer materials can also be used as the matrix for carbon fibers. Due to the formation of metal carbides and corrosion considerations, carbon has seen limited success in metal matrix composite applications. Reinforced carbon-carbon (RCC) consists of carbon fiber-reinforced graphite, and is used structurally in high-temperature applications. The fiber also finds use in filtration of high-temperature gases, as an electrode with high surface area and impeccable corrosion resistance. Molding a thin layer of carbon fibers significantly improves fire resistance of polymers or thermoset composites because a dense, compact layer of carbon fibers efficiently reflects heat.

Precursors for carbon fibers are polyacrylonitrile (PAN), rayon and pitch. Carbon fiber filament yarns are used in several processing techniques: the direct uses are for prepregging, filament winding, pultrusion, weaving, braiding, etc. Carbon fiber yarn is rated by the linear density (weight per unit length, i.e. 1 g/1000 m = 1 tex) or by number of filaments per yarn count, in thousands. For example, 200 tex for 3,000 filaments of carbon fiber is three times as strong as 1,000 carbon fibers, but is also three times as heavy. This thread can then be used to weave a carbon fiber filament fabric or cloth. The appearance of this fabric generally depends on the linear density of the yarn and the weave chosen. Some commonly used types of weave are twill, satin and plain. Carbon fibers can be also knitted or braided.

Fiber Glass
Fiberglass, (also called glass fibre), is a material consisting of numerous extremely fine fibers of glass. Glass-reinforced plastic (GRP) is a fiber reinforced polymer made of a plastic matrix reinforced by fine fibers of glass. GRP is a lightweight, extremely strong, and robust material. Although strength properties are somewhat lower than carbon fiber and it is less stiff, the material is typically far less brittle, and the raw materials are much less expensive. Its bulk strength and weight properties are also very favorable when compared to metals, and it can be easily formed using molding processes. The plastic matrix may be epoxy, a thermosetting plastic (most often polyester or vinylester) or thermoplastic. GRP is an immensely versatile material which combines its light weight with an inherent strength to provide a weather resistant finish, with a variety of surface textures. GRP was developed in the UK during the Second World War as a replacement for the molded plywood used in aircraft radomes (GRP beingtransparent to microwaves). Its first main civilian application was for building of boats, where it gained acceptance in the 1950s. Its use has broadened to the automotive and sport equipment sectors as well as model aircraft, although its use there is now partly being taken over bycarbon fiber which weighs less per given volume and is stronger both by volume and by weight. GRP uses also include hot tubs, pipes for drinking water and sewers, office plant display containers and flat roof systems. Advanced manufacturing techniques such as pre-pregs and fiber rovings extend the applications and the tensile strength possible with fiber-reinforced plastics. GRP is also used in the telecommunications industry for shrouding the visual appearance of antennas, due to its RF permeability and low signal attenuation properties. It may also be used to shroud the visual appearance of other equipment where no signal permeability is required, such as equipment cabinets and steel support structures, due to the ease with which it can be molded, manufactured and painted to custom designs, to blend in with existing

structures or brickwork. Other uses include sheet form made electrical insulators and other structural components commonly found in the power industries.

Storage tanks can be made of GRP with capacities up to about 300 tonnes. The smaller tanks
can be made with chopped strand mat cast over a thermoplastic inner tank which acts as a preform during construction. Much more reliable tanks are made using woven mat or filament wound fibre with the fibre orientation at right angles to the hoop stress imposed in the side wall by the contents. They tend to be used for chemical storage because the plastic liner (often polypropylene) is resistant to a wide range of strong chemicals. GRP tanks are also used for septic tanks. Glass reinforced plastics are also used in the house building market for the production of roofing laminate, door surrounds, over-door canopies, window canopies and dormers, chimneys, coping systems, heads with keystones and sills. The use of GRP for these applications provides for a much faster installation and due to the reduced weight manual handling issues are reduced. With the advent of high volume manufacturing processes it is possible to construct GRP brick effect panels which can be used in the construction of composite housing. These panels can be constructed with the appropriate insulation which reduces heat loss.

Natural Fiber Composites

Among all the synthetic fibers, glass fibers are now dominant due to their low cost (compared to carbon and aramid) and comparatively better physico-mechanical properties. However, the manufacture, use and removal of traditional composite structures made of glass, carbon and aramid fibers are considered negatively due to growing environmental consciousness. For this reason, alternative reinforcement with natural fiber in composites has recently gained attention due to low cost, low density, acceptable specific properties, ease of separation, enhanced energy recovery, C02 neutrality, biodegradability, and recyclable nature. Though the pioneering work in natural fiber thermoplastic composites started in 1970 lot of development has taken place. Among all the natural fibers, jute appears to be the most useful, inexpensive, and commercially available fiber, which can be moulded into a variety of flat- and complex shaped components by exploiting their attractive reinforcing potential.

The potential applications of the natural fibre reinforces plastic that can be produced with this technology are countless. Some areas of interest are:

Automotive industry: fibre reinforced plastics can be used for inner and outer parts.The advantages are that these composites are cheaper, more sustainable and environmentally friendly than glass fibre reinforced composites. The resulting products from those composites can be both re-used and incinerated and do not have to be land filled as glass fibre compounds, which can help in developing cars according to the EU End-of-Life directive. In interior automotive applications they have the advantage of not injuring passengers when an accident occurs because the fibres are soft and not harsh as glass fibres.

Packaging industry: for instance for light weight pallets. The advantages of composite material compared to wood are weight reduction, which safes fuel during transport, and re-use: chipimplementation makes it easy to trace them and they can be remelted into new products at the end of their life-cycle.

Consumer products: any injection moulded product. The advantages are reduction of plastic's use, re-use and flame retandancy. Examples include housing of household appliances like computers, refrigerators and cell phones. The fibre structure of the composite makes these products become less vulnerable for fire and they can be rejected to new products at the end of their life-cycle. In addition, high fibre loads results in significant material cost reduction. Building and construction industry: for instance profiles and roofings. The advantages are cost reduction, flame retardancy and re-use. The fibre structure of the composite makes these products become less vulnerable for fire and they can be remelted into new products at the end of their life-cycle. In addition, high fibre loads results in significant material cost reduction.