A brief presentation on Polymer Matrix Composite (PMC) by the students of Ahsanullah University of Science and Technology (AUST)

1. Application & Manufacturing process of
Polymer matrix ComPosites
(PmC)
By-
13.02.08.040 Mohammad Mehadi Hasan
13.02.08.059 Raju Ahmed
13.02.08.062 Yeadul Islam Sazal
13.01.08.021 Md. Sazzad Hossain
Ahsanullah University of Science and Technology
1

2.  Composite Materials
 Classification of composites
 Polymer & Polymer matrix composite
 Classification of Polymers
 Fibers in PMCs
 Polymer Processing
 Applications Of PMCs
 Limitations of PMC
Contents:
2

3.  Composite Materials
 Made from two or more
constituent materials
 Materials having
significantly different
physical or chemical
properties.
 Produced material have
different characteristics
from the individual
components.
3

4. Classification of composites
Composite
materials
Matrices
Polymer Matrix
Composites (PMC)
Metal Matrix
Composites
(MMC)
Ceramic Matrix
Composites (CMC)
4

5. A large molecule (macromolecule) composed of
repeating structural units (monomer) typically
connected by covalent chemical bonds.
 Polymer & Polymer matrix composite
• Polymer :
5

6.  Consisting of a polymer (resin) matrix and fiber.
 Very popular due to their low cost and simple fabrication
methods.
 Polymer & Polymer matrix composite
• Polymer Matrix Composite (PMC):
6

7. Classification of Polymers
7

8.  Thermosetting and Thermoplastics Polymers
Thermosetting
Polymers
Extensive crosslinking
formed by covalent bonds.
High Thermal stability.
High dimensional
stability.
Low weight.
High rigidity.
Can not be recycled due
to its heavy covalent bonds.
Thermoplastics
No chemical linking between
individual molecules.
Molecules are bonded by weak
secondary bonds like Van der walls
bonds and hydrogen.
Parts can be made and joined by
heating.
Can be remolded, and recycled.
Better toughness and impact
resistance than thermosets.
8

9. Fibers in PMCs:
• Principal fiber materials in FRPs are glass, carbon, and Kevlar 49.
• Less common fibers include boron, SiC, Al2O3 and steel.
• Glass (in particular E glass) is the most common fiber material in today's‑
FRPs; its use to reinforce plastics dates from around 1920.
Various forms:
 Discontinuous (chopped)
Continuous or woven as a fabric
Fibers used
9

10.  Polymer Processing
Forming Processes for Thermosetting matrix composites:
 Pultrusion.
 Resin transfer molding.
 Hand layup and spray up techniques.
 Filament winding.
 Autoclave molding.
Forming Processes for Thermoplastic matrix composites:
 Injection molding.
 Diaphragm forming.
 Film stacking.
 Thermoplastic tape laying. 10

11.  Manufacturing Process of
thermosetting polymers:
Pultrusion:
Pultrusion is a process where composite parts
are manufactured by pulling layers of
fibers/fabrics, bathed with resin, through a
heated die, thus forming the desired cross-
sectional shape with no length limitation.
11

12.  Fibers are pulled from a set of fiber creels and through a
resin bath. It then pass through a performer which gives it
required cross sectional shape. The F & C dies finalize the
required shape & remove excess resin & cure the composite
so that it can be cut into required length.
 Pultrusion process:
12

13.  Pultrusion process:
13

14.  Pultrusion process:
14

15. Advantages:
 High volume productivity
 Rapid processing
 Low material scrap rate
 Good quality control
Potential Problems:
 Improper fiber wet-out
 Fiber breakage
 Die jamming
 Complex die design
 Pultrusion process:
15

16. Applications
 Uses as Panels, Beams, Ladders
 Tool Handles,
 Electrical Insulators,
 Light poles, Hand rails, Roll-up doors etc
 Pultrusion process:
16

17. Resin Transfer Molding
 In the RTM process, dry reinforcement is pre-shaped and oriented into
skeleton of the actual part known as the preform which is inserted into a
heated matched die mold .
 The heated mold is closed and the liquid resin is injected.
 The part is cured in mold.
 Finally mold is opened and part is removed from mold.
17

18. Advantages
 Large complex shapes and curvatures can be made easily.
 High level of automation.
 Simpler than in manual operations.
 Takes less time to produce.
 Low volatile emission
 Cost effective.
 Low skill labor required
Resin Transfer Molding
18

19. Disadvantages
• Mold design is complex.
• Requires Mold-filling Analysis.
• Fiber reinforcement may Move during resin transfer.
Resin Transfer Molding
19

20. Application:
Resin Transfer Molding
• Wind Turbine blade.
• Ship body.
• Car body.
• Truck panel.
20

21. Manufacturing Process of thermoplastics
polymers:
Injection Molding
• Closed Mold process
• Polymer is Mixed with very
short reinforcing fibers
(10- 40%)
• Polymer-fiber mixture in
form of pellets is fed
through a hopper.
• The material is then
conveyed forward by a
feeding screw and forced
into a split mold, filling its
cavity through a feeding
system with sprue gate
and runners.
21

22. Injection Molding (CONT.)
• Reciprocating screw since it
not only rotates but also
moves forward and backward
according to the steps of the
molding cycle.
• It acts as a ram in the filling
step.
• then retracts backward in the
molding step.
• Heating elements, placed over
the barrel, soften and melt the
polymer.
• The mold is equipped with a
cooling system providing
controlled cooling and
solidification of the material.
Cooling
channel
22

23. Injection molding machine
23

24. Injection Molding Machine
24

25. Advantages
 INJECTION MOLDING
o Process can be fully automated
o High productivity & quality
o Price less low
25

26.  DIAPHRAGM FORMING
• Diaphragm forming uses
sheets of reusable
silicon as a carrier
for Thermopreg fabrics
between a heating
section and a forming
section.
• Process needs very low
air pressure.
• Inserting Thermopreg
fabrics between two
silicon sheets.
26

27. • Silicon/Thermopreg
sandwich is
placed in the hot
platen equipment
until it reaches a
temperature of
210 ºC
• Then its placed over
forming machine and
vacuum is created in the
lower site & pressed
from upper site
• Transfer the forming
unit and apply
positive air below
100 ºC.
 DIAPHRAGM FORMING
27

28. Diaphragm Forming Machine
28

29. ADVANTAGES:
 Components with double curvatures can be formed.
 Compliant diaphragm do the job for simple components.
 DIAPHRAGM FORMING
29

30.  Types of processing discussed at a glance
30

31. APPLICATIONS OF PMCs
Aerospace and Military Aircraft
 The aerospace industry is estimated to consume about 50
percent of advanced composites production in the United
States.
 The primary matrix materials used in aerospace applications
are epoxies, and the most common reinforcements are
carbon/graphite, aramid (e.g. Kevlar), and high-stiffness glass
fibers.
 Compared with metals, the principal advantages of advanced
composites in aerospace applications are their superior
specific strength and stiffness, resulting in weight savings of
10 to 60 percent over metal designs.
31

32. APPLICATIONS OF PMCs
Aerospace and Military Aircraft
Composites in Boing 787 body
32

33. Automotive Industry
 The principal motivation for introducing PMCs is cost savings
Because the industry is mature and highly competitive.
 Because of greatly improved corrosion resistance PMC
automobiles could last 20 or more years compared to the current
average vehicle lifetime.
APPLICATIONS OF PMCs
33

34. APPLICATIONS OF PMCs
Automotive Industry
34

35.  Construction
A potentially high-volume market for PMCs lies in construction
applications especially in.. Construction of
 Buildings
 Bridges
 Housing
 Lampposts
 Smokestacks
 Highway culverts.
APPLICATIONS OF PMCs
The smith road bridge all-composites
bridge, Ohio, USA
35

36.  Medical Devices
The impact of PMCs on orthopedic devices such as
 Hips
 Knees
 bone plates,
 intramedullary nails is expected to be especially
significant.
APPLICATIONS OF PMCs
36

37.  Advantages of PMC
 Good inplane stiffness and strength.
 Low density.
 Relatively low cost.
 Corrosion resistance.
 Low coefficient of thermal expansion.
 Relatively mature technology.
 Excellent in-service experience.
37

38.  Limitations of PMC
 Low maximum working temperature.
 Sensitivity to radiation and moisture.
 Processing temperature are generally higher than
those with thermosets.
 Required special processing equipment.
 Thermoset resins have poor impact resistance.
38

39.  Conclusion
In 21st
century we are in need of light but stronger
materials. From automobile to aerospace, medical ,
military technology and even in household we need
heavy duty, corrosion resistant material. Here comes the
composites with all those specifications. And day by day
the field of composite materials is getting stronger.
Among all the composites Polymer Matrix Composites
(PMC) have a strong place due to its specialization.
39

40. Thank You
40