Exam questions Flashcards

1
Q

What is a hybrid composite?

A

Matrix + 2 reinforcements

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2
Q

What length of fiber is necessary for fiber pull out?

A

Shorter than lc

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3
Q

There is a growing interest in thermoplastic matrix composites. Give at least three reasons for this.

A

Possibility to re-process by melting + reshaping

short cycle production
long shelf-life
increasing service temperature being enabled by several thermoplastics
dimensional stability
resistance to moisture
good to excellent dielectric properties
abrasion resistance.
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4
Q

There are certain disadvantages in using thermoplastic matrices Give at least two such hindering reasons.

A
  • expensive tools and processing equipment due to high pressures and temperatures involved
  • high viscosity during manufacturing
  • less stiff and stiffness decrease with T
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5
Q

What is Ps in Weibull?

A

Probability of survival

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6
Q

Is the value of m (Weibull shape parameter) for carbon fibres typically higher or lower than that for aramid fibres?

A

CF has a large variability in strength which means that the Weibull parameter is low.

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7
Q

Unsaturated polyester (UP) is common matrix for composite materials. During the polymerization four compounds are active. Which of these materials is important for the cross-linking?

A

Styrene

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8
Q

Why are fibres so interesting as reinforcing elements in composites? Give at least two reasons.

A
  • They are flexible
  • materials are typically more strong in fiber form
  • they have low probability of defects which gives a positive influence on mechanical properties.
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9
Q

With ceramic matrix composites (CMC)/metallic matrix composites (MMC) in mind, what are the three forms of interfaces between two phases in a composite?

A

• Direct bonding with no intermediate layer
• Intermediate layer in form of a solid solution of the matrix and dispersed phases
constituents
• Intermediate layer in form of a third bonding phase (adhesive)

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10
Q

What’s the difference between trans-granular and inter-granular cracking? Explain how the fracture surface looks like

A

Inter-granular fracture is most likely when the grain boundaries are weak and the individual grain boundaries/facets are visible on the fracture surface. In trans-granular (cleavage) fracture, the crack passes through the grains. The fracture surface may be smooth or shows small steps.

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11
Q

Explain in detail how fibres can reinforce a brittle (ceramic) material

A

When the crack grows in the matrix, the reinforcement (fibers) remains intact and bridge the crack. This promotes multiple cracking – each contributing its own energy and thereby raising the overall dissipation. When the fibers do break, the breaks are statistically distributed, leaving ligaments of fibers buried in the matrix. The pullout, as the crack opens up, dissipates more energy by friction.

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12
Q

Which parameter in the Nielsen equation does not appear in the Halpin-Tsai equation?

A

Parameter Ψ does not appear (or the maximum packing fraction Φmax).

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13
Q

Describe what is meant by the critical fibre length. Give at least two quantities that determine the critical fibre length.

A

General description of the critical fibre length including that the fibre can be pulled out of
the matrix when the fibre length is shorter than the critical fibre length

Interfacial shear strength, fibre strength, fibre diameter

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14
Q

Roughly, what is that critical length typically for practical polymer matrix composites?

A

Millimeter range

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15
Q

What is a symmetric laminate

A

A symmetric lamina with matching plies on each side of the midplane

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16
Q

What is a cross-ply laminate?

A

A cross-ply laminate consists of plies oriented either in 0° or 90°.

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17
Q

In case of thermosets, what are the three elementary tasks that must be achieved during
processing/manufacturing of a PMC product (except curing)?

A

There are three elementary tasks carried out during processing of a PMC: fibres must be
wetted out, forming (shaping) must take place, and depending on the manufacturing route, drainage of resin must take place.

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18
Q

In which way does shrinkage influence moulding (processing) of PMCs?

A

High resin shrinkage can contribute to moulding defects, such as internal stress, warpage and sink marks, however, can be desirable for easy mould release.

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19
Q

From composite manufacturing viewpoint, injection moulding (IMCs) is attractive, and thus widely applied. However there are some disadvantageous features. Mention at least 1 important advantage and 1 important disadvantage.

A

+ fast cycle timme

  • Fibers get crushed during process
  • Expensive moulds is also a drawback.
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20
Q

Describe briefly in words vacuum infusion moulding (also called vacuum injection moulding). Mention at least two common applications.

A

A stack of dry fibres is placed between a rigid mould half and a flexible and airtight bag. The bag is sealed to the mould, except at certain positions being open for resin inlets and outlets. Liquid resin is then forced into the stack by reduction of the pressure at the outlets, while keeping the pressure atmospheric at the resin inlets.

Common applications include: boats, yacht hulls, offshore structures, vehicle body panels, wind turbine rotor blades and others.

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21
Q

Give at least two ways or requirements for obtaining a good wetting of fibres and particles by a liquid (or resin).

A
  • Low contact angle (clean surface)
  • low viscosity of the liquid
  • no entrapment of air (smooth surface).
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22
Q

Name at least three types of interfacial bond that may form between the matrix and fibre. Which one gives a particularly high contribution to interfacial strength?

A
  • Molecular entanglement
  • electrostatic attraction
  • presence of anionic groups
  • chemical bonding
  • mechanical keying.

Chemical bonding highly contributes to interfacial strength.

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23
Q

Why should you use low frequency and not high one when measuring the S/Nf plot?

A

Low frequency should be used (say below 10 Hz) to avoid heat build-up.

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24
Q

List three mechanisms increasing PMCs toughness, and select one and explain it.

A
  • Crack deflection, delamination
  • use of more tough matrix
  • frictional sliding during fibre pull-out.
  • debonding
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25
Q

Sandwich structures consist in most cases of a core and two facings (skins). There are three primary types of core structures.

A

Honeycomb , foam (cell structure) and balsa

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26
Q

Explain/sketch what is exfoliation and intercalation for layered-silicates (montmorillonite),
to obtain nanoplatelets.

A

In order to obtain clay nanocomposite material, tactoids have to be intercalated and finally delaminated in the surrounding matrix. The mechanism of exfoliation during the melt processing consists of a combination of shear
and diffusion of polymer chains in-between the layered silica. During shearing the tactoids experience dis-
placements in the shearing direction, thus facilitating the diffusion process. Furthermore, along with the penetration of polymer chains within the tactoids,
the layers become prone to breakage and exfoliation due to the shear forces.

A common method to enhance exfoliation is through the cation exchange process.

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27
Q

Mention at least 2 critical issues in preparing carbon nanotube (CNT) composites.

A
  • dispersion
  • alignment
  • manufacturing
  • cost effectiveness.
  • de-agglomeration
  • functionalization (CNTs are rather inert from the start).
  • toxic aspects.
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28
Q

Give two examples of thermosets and thermoplastics.

A

Epoxy, UP (unsaturated polyester)

PP (Polypropylen), PVC (Polyvinylcloride), PA (Polyamide)

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29
Q

Give two examples of thermosets and thermoplastics.

A

Epoxy, UP (unsaturated polyester)

PP (Polypropylen), PVC (Polyvinylcloride), PA (Polyamide)

30
Q

Describe what is the fundamental difference between thermosets and thermoplastics

A

A thermoset polymer matrix is created using and uncured liquid and a curing agent through a cross-slinking process whereas thermoplastic materials are created using a polymerization reaction from a monomer.

31
Q

What can be said about thermosets and thermoplastics from environmental/recycling point of view?

A

Thermoplastic PMC components can be directly re-processed by melting + reshaping. This is not possible for thermoplastics, where the degradation temperature is lower than the pro-
cessing temperature.

32
Q

Composite materials have generally different characteristics compared to monolithic materials. Name two fundamental differences valid for fiber reinforced composites.

A
  • anisotropy: unidirectional, UD, fibre composites are anisotropic – that is their properties vary significantly when measured in different directions. In addition , one or more of the constituents may exhibit inherent anisotropy as a result of their crystalline structure.
  • heterogeneity: by definition composites are heteheterogeneous. There is a large interface area implying that the reinforcement-matrix interaction is of immense importance.
  • coupling phenomena: for conventional isotropic materials coupling between different loading modes, such as bending-twisting, is not observed. This is not the case for fibre reinforced composites where various couplings can take place, depending on the structure of the composite
33
Q

what is the fundamental difference to a normal distribution (represent graphically and explain). Why would a normal distribution be unsuitable?

A

The normal distribution is symmetric, i.e. for
every weak fibre there is a corresponding strong one. The Weibull distribution is non-symmetric or skew i.e. for a given collection of fibers there will be more weak fibers than strong ones.

34
Q

what is the significance of the Weibull parameter for a batch of i.e. carbon fibers?

A

m represents the degree of fibre flaw sensitivity (the higher the m, the less variable is strength). m is an inverse measure of the width of the distribution.

35
Q

Magnesium has lower density and slightly lower melting temperature as compared to aluminium. However,
aluminium is the most frequently used matrix material in MMCs. Why?

A

Aluminum is the most common metal matrix material, due to its low density, its high processability (associated with the low melting temperature of 660°C), and its high ductility (associated with its fcc crystal structure).
Magnesium is even lower in density than aluminuim and also has a low melting temperature (650°C), but it
suffers from its relatively low ductility (consequence of the hcp crystal structure and the fewer slip systems).

36
Q

In comparison to monolithic alloys, machinability of MMCs is poor. Explain the different ways of abrasive way
and name alternative machining methods.

A
  • Three body abrasive wear: freely moving particles
  • Two body abrasive wear: embedded hard particles
  • Two body abrasive wear: hard rough surface

The main problem is that the hard abrasive rein- forcement in most MMCs causes rapid tool wear during machining (high machining costs). Non-con- ventional machining processes, such as Electro Discharge Machining (EDM), laser cutting and Abrasive Water Jet (AWJ).

37
Q

Stress corrosion cracking is a possible failure mechanism in CMCs. Explain what is occurring?

A

Environmental effects at the crack tip (combination of stress and corrosion): A water molecule diffuses to the crack tip, chemisorbs, and rotates such that the long pairs of the oxygen are aligned with the unoccupied electron orbitals of the Si atom. The reaction which involves braking of Si-O bonds is: Si- O-Si + H2O 2Si-OH.

38
Q

Name manufacturing procedures for thermoplastic or thermoset matrices

A
  • filament winding
  • pulltrusion
  • Vacuum infusion moulding
  • compression moulding
  • Resin Transfer moulding
39
Q

What is considered the most critical manufacturing defect influencing the mechanical properties, most often in a negative way? Hint: the defect is formed during processing of the non solidified matrix.

A

One of the most critical manu- facturing defect is the presence of voids. Voids are formed during processing and originate from:
• impregnation, wetting-out of fibers
• resin cavitation during deformation
• air or vapors entrapment (from resin viscosity control, relative values of fibre and resin surface energies, moisture, chemical contaminants in the resin, styrene monomer, they may re- main dissolved in the resin mix and volatilize during elevated temperature curing)
• too high viscosity
• emulsification, when fibers are pulled through the liquid resin.

40
Q

What is a pre-preg and what is it used for? What are the advantages of using pre-pegs in manufacturing applications?

A

Pre-preg is a short form for preimpregnated fibres. A prepreg is a mixture of fibers, resin and additives, in the form of thin sheet, used for convenience and for speeding up the manufacturing process

41
Q

Name the fundamental hypotheses implied for the determination of the stress-strain relationship of a UD ply/ lamina. As a result of these hypotheses, using the contracted notation, the stress tensor has only three components [sigma1 sigma2 sigma6]. What is their significance, i.e. what components do they represent?

A

A UD lamina/ply is a special class of of reduced anisotropy known as orthrotropy, the lamina is thin and has transverse isotropy (see also Figure D.2). External loads are assumed to be in one plane, i.e. we have a plain state of stress. From constitutive point of view both the fibers and the matrix are considered linear- ly elastic materials.

An analysis corresponding to this case is called the classical laminate theory. As a result of these simplifications the total stress tensor is reduced to having three components, two normal components,
σ1, σ2, and one shear component, σ6.

42
Q

(a) antisymmetric laminate

(b) a balanced cross-ply laminate

A

a) An antisymmetric laminate has plies of identical material and thickness at equal positive and negative distance z from midplane, but the ply orientations are antisymmetric, that is for a given positive angle, a negative angle occurs at the corresponding position.
b) has a equal numbers of identical 0° and 90° plies

43
Q

Halpin-Tsai equation was used to determine the material properties in the transverse direction, as opposed to the rule of mixtures.
(a) Why is this customary?
(b) Furthermore, it is common to use a generalized expression, namely the Lewis-Chen relation .
What improvements does the latter bring over the Halpin-Tsai relation?

A

The rule of mixtures equation does not give accurate quantification of transverse properties, e.g. it underestimates the transverse stiffness of UD long fibre composites. The generalized form of Lewis and Nielsen includes the additional parameter Ψ, that takes into account the maximum fiber packing fraction.

44
Q

The strength of the composite depends on the interface strength. Complexity in the near-fibre region can stem
from a wide variety of factors. Name four of them and explain briefly.

A

• difference in thermal expansivity of fibre and that of matrix, this leading to residual strains and stresses (differential thermal contraction or expansion)
• difference in thermal conductivity of fibre and that of matrix can influence the matrix; for example carbon
fibre is thermally more conductive than the polymer matrix and this may reduce the temperature in the matrix during cure and thus lower the crosslinking density
• presence of fibre surface can influence the cross-link density in matrix adjacent to the fibre
• volume contraction on cure (thermosets) can introduce internal stresses, and this can be particularly pronounced close to the fibre
• generally different Poisson ́ s ratio of the matrix and that of the fibre, can lead to a fibre-matrix mating pressures
• spherulites can nucleate at fibre-fibre contact points. Furthermore, the volume contractions accompanying crystallization will set up residual stresses which may affect the behavior
• sizing and binder can be present in the close to fibre region
• water in-take can take place along fibre-matrix interface.

45
Q

Name two bonding mechanisms and briefly describe them

A

Interfacial bonds formed by:

(a) molecular entanglement following interdiffusion,
(b) electrostatic attraction
(c) anionic groups at the end of molecules attracted to a cationic surface
(d) chemical bonding
(e) mechanical keying

46
Q

How is it possible to measure the interfacial strength? Name one measurement method and briefly describe it

A

Microbond test: Fine droplets are applied to a single fiber and cured, Then the fiber is pulled through a gap between knife edges, the separation of which is controlled by a micrometer

47
Q

Consider an unidirectional long-fiber reinforced composite subjected to an arbitrary load. There are three failure modes/strengths. Name them.

A

(a) Axial tensile strength
(b) Transverse tensile strength
(c) Shear tensile strength

48
Q

Three of the most common failure criteria that include the effects of multiaxial and off-axis load are the (i) maximum stress (ii) maximum strain and (iii) the Tsai-Hill criterion:

(a) what are the conditions that need to be fulfilled for (i) and (ii)?
(b) which of the three criteria is the most easy to implement and which one is the most conservative?

A

(a) (i) Maximum stress criterion: failure occurs when any principal stress is equal to or exceeds the corresponding ultimate strength.
(a) (ii) failure occurs when any principal strain exceeds the corresponding ultimate strain
(b) it can be argued that the most convenient method to implement is the maximum stress method, if the stresses are given. The most conservative is the Tsai-Hill criterion (interactive) and predicts experimental data more accurately. However, it should be noted that there is no single criterion which is universal for the general case of any fibrous composite material subject to a multiaxial stress system.

49
Q

What is cm?

A

cm represents the critical crack length, below which a crack is stable, i.e. cracks will not spread. Upon ex-
ceeding cm the crack will spread catastrophically leading to failure.

50
Q

A fiber-reinforced PMC (square packing) is subjected to a load perpendicular to the fiber direction σ2, as shown in the figures below. When at the ultimate stress in that direction is reached, σ2 = σ2u, a fracture is developing perpendicular to both the applied load and the fiber direction. Sketch the fracture trajectory if

(a) the interfacial bond strength, σa, is smaller than the matrix ultimate stress, σmu
(b) the interfacial bond strength is greater than the matrix ultimate stress.
(c) Which of the two outcomes is more desirable? Motivate your answer!

A

a) by the fibers

b) in the matrix

51
Q

Adhesion between fibre and matrix determines crack run in the composite. describe where to find good, medium and poor adhesion

A

Multiple cracking as in case of good adhesion leads to dissipation of the energy and slows down the crack. Poor adhesion as in the first case leads to fracture and easy fibre pulling.

52
Q

what is the fundamental difference between a typical S/Nf (strain-controlled test) plot for a polymer matrix composite against a typical metallic?

A

For metallic a fatigue limit (endurance) is observed. below the fatigue limit, no fatigue failure occur. for many fiber reinforced polymer composite this limit is not observed.

53
Q

What is considered to be the origins of damping phenomena in polymer matrix composites? Is the linear elasticity approximation in the classical laminate theory able to explain damping? What constitutive hypothesis
needs to be considered?

A

Damping can be understood as any phenomenon within the body of the material in which energy is dissipated. there are 2 possible origins for damping behavior in polymer composites as the linearly elastic hypothesis cannot be used. The one elaborated in our course is based on the linearly viscoelastic constitutive character of the composite constituents, hence linear viscoelastic damping, mechanism which dominating in composite

54
Q

Although exhibiting multiple remarkable properties, name three main current critical issues/challenges in the
production of CNT.

A
  • Controlled production i.e. production of CNTs with uniform properties
  • toxicity questions, i.e. tackling the environmental, helt and safety aspects of engineering nanoparticles generally
  • cost although the cost of multi wall nanotubes has strongly decreased recently, this has not taken place in the case of single wall nanotubes.
55
Q

The matrix of a composite is important for the composite performance and in some cases controls its per- formance. Summarize the importance of the matrix and criteria for matrix materials selection in a PMC

A
The matrix protects the fibers from abrasion, in transverse direction only matrix controls the properties, Properties like flammability is controlled by matrix
• Service temperature
• Manufacturing aspects
• Size of composite component
• price
• environmental issues
56
Q

What factors contribute to the fracture toughness of ceramics?

A

• The volume fraction of reinforcement
• Young’s modulus of matrix and reinforcement: If a matrix is reinforced with high modulus, high strength
fibers, then more stress can be carried by the fibers.
• Strength of the matrix/reinforcement interface: In fiber-reinforced composites a strong interface can lead to
transfer of stress from the matrix to the fibers. A weak interface can lead to de-bonding and crack deflection.

57
Q

Particle strengthened metal-matrix composites. Cermets are a particle strengthened MMCs.

(a) Describe how they are produced?
(b) What do they commonly consist of (materials) and why (properties)?
(c) What is the most common application area for cermets?

A

Cermets (or actually cemented carbides) are produced by powder metallurgy and are composite materials made of ceramic (cer) and metallic (met) materials that combines the properties of both a ceramic, such as high temperature resistance and hardness, and those of a metal, such as the ability to undergo plastic defor- mation. The metal (mostly Ni, Mo and Co) is used as a binder for an oxide, boride, carbide, or alumina. (Com- mon cemented carbides are based on tungsten carbide (WC), titanium carbide (TiC), and chromium carbide (Cr3C2); Tantalum carbide (TaC) and others are less common; Metallic binders: usually Co or Ni).
Application: WC-Co is used as cutting tools; other applications: wire drawing dies, rock drilling bits and other mining tools, dies for powder metallurgy, indenters for hardness testers.

58
Q

(b) Compare the ROM and Halpin-Tsai values: what do the results tell us of the validity of ROM?
(c) What additional quantity is considered to further improve the determination of elastic constants, i.e. in the Lewis-Chen generalized Halpin-Tsai?

A

ROM works better in fiber direction
HT works better in transverse loading
For HT epsilon22 is overestimated

59
Q

Name 3 failure mechanisms/scenarios that can when considering the longitudinal compressive strength of a UD fiber composite.

A
  • fiber compressive failure
  • microbuckling/microinstability
  • fiber debonding
  • microcracking
60
Q

What is the main advantage sought by using nanocomposites in contrast to traditional micrometer-sized reinforcement?

A

Materials property improvements, e.g. mechanical, thermal, dielectric, barrier, flammability etc., can be achieved at much smaller particle contents in comparison to traditional micrometer-sized particles.

61
Q

What are the main advantages of melt processing of polymer nanocomposites as opposed to in-situ polymer- ization and solution processing?

A

In-situ polymerisation is better in a manufacturing view. Resin manufactures are able to dedicate a production line to nanocomposite.
Solution processing is not as attractive due to environmental issues.

62
Q

CMCs are used in thermal barrier coatings. Explain their purpose and how they are (schematically) built up

A

Thermal barrier coatings are used in gas turbines to insulate the underlying material from high tempera-
ture loads. The part is often made of a superalloy and a ceramic is applied as top coat. Due to the different thermal expansion coefficients, a so called metallic bond coat is applied in between.

63
Q

Which properties/features are advantageous for thermal protection? Name at least three and explain how they contribute.

A

(b) For thermal protection, e.g. a low thermal conductivity, presence of pores and many interfaces are ad- vantageous. A material with low thermal conductivity is not conducting heat (e.g. in ceramics there are
only phonons contributing to heat conduction which are easily scattered); interfaces and pores are scat-
tering electrons and phonons

64
Q

There are at least three conceptually different ways in which a mould of a given shape can be manufactured.
Give an example of a mould type and describe briefly the advantages and disadvantages of using it.

A
  • Direct manual fabrication
  • Direct machining from block of material
  • Use of master model

+ High degree of precision
+ Several identical moulds
- time consuming
- High cost

65
Q

Which is the only (common) continuous composite manufacturing process?

A

Pulltrusion

66
Q

eeping in mind crack deflection, would you need to increase or decrease the toughness of the interphase in order to increase the composite toughness?

A

decrease

67
Q

Sketch the dependence of A/V vs. a for a reinforcing unit having cylindrical shape. A = surface area, V = volume, a = aspect ratio, l= length, d= diameter. What are the most advantageous configurations for reinforcing materials?

A

Platelets and long fibers. Thus reinforcement-matrix interaction is maximized through the interface

68
Q

What are the constituents of a moulding compound? Why are the reasons for using them?

A

• reinforcement
• resin
• filler and additives
It is not convenient to manufacture a composite component starting with separate fibres and matrix. Moulding compounds are used to increase production rates and convenience.

69
Q

From composite manufacturing viewpoint, injection moulding (IMCs) is attractive, and thus widely applied. However there are some disadvantageous features. Mention at least 1 important advantage and 1 important disadvantage.

A

For composites processing, the polymer is mixed with short cut fibers to form pellets (or granulates) few mm in length, which are fed into the hopper of the injection moulding machine, and injected into a mould in the same manner as conventional, neat thermoplastics. This technique is probably the fastest manufacturing route for composites. however intensive fiber breakage takes place and as a result a strong fiber length distribution has to be expected. Due to varying conditions of the mould there is a strong fibre orientation distribution, and hence different anisotropy in different places of the part. It should be also noted that the wear on the machine is high due to the abrasive action of some fibers.

70
Q

Name three of the basic assumptions associated to the Classical laminate theory for the analysis of compos- ite laminates.

A
  1. In the classical laminate theory the following assumptions are used:
    (i) both, matrix and fibre are linearly elastic materials
    (ii) There is no slip between the fiber and matrix
    (iii) external loads will all be in one plane (2D)