Compounding of Plastics & Composites

Compounding

Alloying

Blending

Filling / Adding

Difference?

Compounding

Alloying Single Tg Synergistic Properties

Blending Multiple Tg Average of Properties

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Additives, Fillers & Extenders?

Additives, Fillers & Extenders? Additives.Fillers.Extenders

Quality .Quantity

More Cost.Less
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Additives and Fillers: To change and improve 1.Physical 2.Mechanical 3.Processing properties

Additives and Fillers: 1.Colorants 2.Plasticizers 3.Flame retardants 4.Antistatic agents 5.Heat Stabilizers 6.Anti-oxodants 7.UV Light Absorbers 8.Blowing Agents 9.Coupling Agents 10.Fillers
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1.Additives:

COLORANTS

1.Additives: COLORANTS
Provide colour-fastness when exposed to light, temperature, humidity, chemicals

Without reducing other properties like Flow during processing, Resistance to chalking & Impact strength

2. Additives:
PLASTICIZERS

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2.Additives: PLASTICIZERS

Enhance flexibility, resiliency, & melt flow of plastics Act like internal lubricants by reducing VanderWaals forces between polymer chains & by preventing them from intermeshing

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LUBRICANTS: Enhance resins Processabilty & Appearance of final product

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3.Additives:
FLAME RETARDANTS

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3.Additives: FLAME RETARDANTS Reduce flammability of plastics

Insulate plastic, create endothermic cooling reaction, coat plastic excluding oxygen

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4.Additives: ANTISTATIC AGENTS (De-staticizers)

Reduce build up of electrostatic charges on surface of plastics

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5. Additives: HEAT STABILIZERS Prevent degradation of resins during processing when melts subjected to high temperatures

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6. Additives: ANTIOXIDANTS

Protect materials from deterioration through

oxidation brought on by heat, light / chemically induced mechanisms Deterioration is manifested by Embrittlement, loss of tensile properties & discoloration

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7. Additives: UV LIGHT ABSORBERS stabilize colour & lengthen life of product because virtually every plastic degrades in sun-light through discoloration & loss of
physical properties Years of outdoor Exposure

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8. Additives: BLOWING AGENTS Produce cellular / foam structure in a plastic mass

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9. Additives: COUPLING AGENTS

Improve bonding of plastic to inorganic filler materials, such as glass fibres Silicones and Titanates used Magneto Cover Story
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10. Additives:
FILLERS Inorganic (e.g: Glass fibres )

Organic (e.g:wood)
Mineral (e.g: Calcium Carbonate, Silica & Clay) Used with thermosetting resins Like Phenolics, Ureas and Melamines
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Because Properties of extended plastic often decrease, use limited to less critical applications
One of the most widely used filler is wood flour (Which country?) Maple Flour

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Polymer Composites

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Objective of Capsule: What are composites Why do we need composites Typical Applications

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Composite: Any material made of more than one component

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+ 4 + 5?
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1.Composite?

2.Macintosh?
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Macintosh

Why do we make composites? To make a material that has the properties of both its components.
We combine the water-resistance of Polyisoprene and the comfort of Cotton.
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Composite
Fibre Matrix

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Composite
Fiber
Glass / Kevlar / Carbon / PE Matrix

TS/ Epoxy / Polyimide

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Composites

Particle Based
Magneto Cover

Fibre Reinforced

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Composites

Particle Based Laminar

Fibre Reinforced

e.g: FERAL, Plywood, ARAL,

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Particulates:
Spheres Rods Flakes Aspect Ratio ~1

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Composite Properties affected by: Size, Shape Amount & Distribution Modulus

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Fiber Composites

Short Fiber Discontinuous

Long Fiber Continuous

Relationship between Modulus & Length

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Particle Board

MDF Board

Plywood

Isotropy
(Random Particulate)

Properties Orthotropy
(Continuous Fiber)

Anisotropy
(Aligned Short fiber)

Fiber embedded in the matrix in order to make the matrix stronger Advantages of Fiber Reinforcement in cars

Strong and light

Stronger than steel, but weigh much less

Can be used to make automobiles lighter

More fuel efficient Pollute less

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What Fibers Do?

Fiber-reinforced composite

Fiberglas

Pour mix of Styrene & Polyester over mass of glass fibers Styrene & double bonds in polyester react by Polymerization to form cross-linked resin Glass fibers trapped inside, acting as reinforcement

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Fibers not lined up in any particular direction

Tangled mass

We can make composite stronger by lining up all fibers in same direction

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Any suggestion to make it strong in both directions?

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42

What does the matrix do for fiber? Why not just use fibers by themselves? 1.Function of Matrix Matrix holds the fibers together Loose bundle of fibers wouldn't be of much use

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2. Function of Matrix
Though fibers are strong, they can be brittle Matrix can absorb energy by deforming under stress.(i.e) matrix adds toughness to composite

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3.Function of Matrix While fibers have good tensile strength, they usually have low compressive strength That is, they buckle when you squash them Matrix gives compressive strength to composite

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Why Glass Fiber?

Economical

As fiber, strong & flexible!

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Properties of Glass Fibers Glass Sp. Tensile Tm Applications 0C Strength Grad Gravity MPa e A ?
E ECR ? ?

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Properties of Glass Fibers Glass Sp. Tensile Tm Applications 0C Strength Grad Gravity MPa e A 2.50
E ECR 2.58 2.62

2.48

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Properties of Glass Fibers Glass Sp. Tensile Tm Applications 0C Strength Grad Gravity MPa e A 2.50 3040
E ECR 2.58 2.62 3450 3625

2.48

4590

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Properties of Glass Fibers Glass Sp. Tensile Tm Applications 0C Strength Grad Gravity MPa e A 2.50 3040 996
E ECR 2.58 2.62 3450 3625 1065 1204

2.48

4590

1454

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Properties of Glass Fibers Glass Sp. Tensile Tm Applications 0C Strength Grad Gravity MPa e A 2.50 3040 996 Good Chem. Resistance E 2.58 3450 1065 Electrical Grade (PCB) ECR 2.62 3625 1204 Elec.+ Chem.
S 2.48 4590 1454 Strength + Thermal
Stability (Air-craft)
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C Grade Coupling Agent Imparts lubricity Resin Compatibility Dimensional Stability Adhesion with Matrix Protection from handling damage

Fire-Proof Kevlar West

Carbon fiber > Kevlar

Wrt UTS
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Kevlar: Tends to be tougher Can absorb more energy without breaking Can stretch a little to keep from breaking, more so than carbon fiber can

Can withstand more force without breaking

Carbon-Kevlar
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Spectra Strongest, lightest man-made fiber Bullet resistant composite

10 times stronger than steel

40 percent stronger than aramids Light enough to float on water Exhibits superior resistance to chemicals,Water and UV light

Excellent vibration dampening,flex fatigue and internal fiber-friction characteristics

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Spectra fibers are used in

Police and military ballistic vests

Helmets and armored vehicles Sailcloth Fishing lines Cut-resistant gloves Safety apparel

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20%

Reinforcement Particles / Fibers 80%

80% Matrix 20%

Continuum of Composites by Volume

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Matrix needs only to wet & form a continuous phase around the reinforcement

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Properties of Composites
Matrix Reinforcement Properties Improved
Mechanical Strength Elevated Temp. Strength Chemical Resistance Anti-static Electrical Resistance EMF Shielding Flexibility Wear Resistance Energy Absorption Thermal Stability 59

Thermosets Carbon Thermoplasts Glass Organic Fiber Glass Bead Ceramic Particle Metal wire

Classification Based on Form of Reinforcement: Particulate Fiber Laminar

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Applications of Composites

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Mag - Graphite Composite Tennis Racquet

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Golf Club

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Should be As light as possible As strong as possible Can bend but should not break

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65

First Flight :4 January 2001

Crew one (pilot)

Maximum speed:1.8 Mach Range:850 km Service ceiling:15,250 m Length:13.20 m

LCA Tejas

Wingspan:8.20 m Height:4.40 m Weight

Empty:5,500 kg
Loaded:8,500 kg
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Conclusion:
Generally Composites are characterized by: 1. Density 2. Specific strength 3. Specific Stiffness 4. High-temperature performance limits 5. Wear resistance

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Relationship between weight & cost?

Cost

?
Weight
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Relationship between weight & cost?

Cost

Aero Space

Automotive

Weight
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Think Composites

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Thank You
pgschool@nttf.co.in
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