Inför tentan Flashcards
What does CFRP consist of?
Carbon fiber reinforced plastics. Carbon fibers and plastics.
Name three advantages with PMC.
Specific stiffness
Specific strength
Light weighted
Corrosion resistance
Name three disadvantages with PMC.
Temperature range
Long manufacturing time
Expensive
Recyclability
Why is it easier to manufacture thermoset-based composites than thermoplastic-based composites?
No need to melt anything. Lower viscosity, easier to impregnate the fibers
Name the three most common types of fibers in PMC.
Carbon, Aramid, Glass
Name two advantages with carbon fiber.
Very strong
Very stiff
Thermal and electrical conductivity
Excellent fatigue properties
low thermal expansion
good X-ray permeability
Name two disadvantages with carbon fiber
Expensive
Low failure strain / brittle
What does the abbreviation “IM” means regarding carbon fibers
Intermediate modulus
Name two advantages with glass fiber.
High strength
Good thermal properties
Good corrosion resistance
Good thermal and electrical insulation
Low price
Name two disadvantages with glass fiber.
Low stiffness
Sensitive to moisture
Sensitive to notches
What is the difference between S-glass fibers and E-glass fibers?
S-glass more expensive
Describe E-glass
E-glass: Electrical Grade, most common type (99% of all continuous fibers)
Describe S-glass
S-glass: High strength grade, 30% higher strength and 20% higher stiffness than E-glass. More expensive
Name three common types of natural fibers.
Hemp, flax, cotton, ramie, jute, coconut, wood
What does NCF mean?
Non crimp fabric
Describe the structure of NCF.
Fabric that doesn’t crimp. Better compression properties? Unidirectional layers/ CSM are stitched together to prevent movement with polyester
Higher stiffness and strength compared to weaves
Name the three most common types of thermosets in PMC.
Epoxi, Polyester, Vinylester
Name two advantages with epoxy
Mechanical properties
Thermal resistance
Chemical resistance
Electrical insulation
Excellent adhesion
Low shrinkage at cure
Name two disadvantages with epoxy
Allergic reactions
Toxicity
Poor UV resistance
Expensive
What is important to remember when you work with epoxy?
Gloves and ventilation.
Name two advantages with UP.
Unsaturated polyester
Good mechanical properties
Low viscosity
Easy curing
Low price
Name two disadvantages with UP.
Low temperature resistance
Large shrinkage at cure
Problem with styrene evaporation. Good ventilation necessary!
Why are glass fibers covered by sizing?
To improve (chemical) adhesion to the matrix.
Protect the fibers.
Avoid static electricity.
Keeping the fibers in bundles.
Why is it normally good with a strong bonding between the fibers and the matrix?
Evenly disperse the force.
Preventing debonding / delamination
Why is it not so wise to use old glass fibers?
The sizing dries with time –> poor bonding
Why are residual stresses formed in PMC?
Different thermal expansion coefficients
Name two advantages with biocomposites.
Renewable resources
Easy to market
Low price
Name two disadvantages with biocomposites.
Moisture sensitive
Variances in the fibers due to different growth
Relatively low strength
Long-term properties
Name two common nano-reinforcements in composite materials.
Carbon nanotubes
Nanoclay
Cellulose fibrills
Why does unsaturated polyester normally contain styrene?
To lower the viscosity (30-35%)
How is curing of unsaturated polyester initiated?
Adding a free radical catalyst –> start the chain reaction of polymerization
What’s the purpose of adding inhibitors?
To prolong the working time. Control the curing.
Only prolongs the reaction ~ 2 hours → need more time? change catalyst! the inhibitor can affect the properties
Which resins do often contain an inhibitor?
polyester resins
What’s the purpose of adding accelerators?
Speeding up the curing process.
green/bluish due to cobalt
Why should accelerators and catalyst never be mixed directly together?
they can burn/explode
If you want to add both accelerator and catalyst what should you do?
1)add the accelerator 2) stir & dissolve 3) add the catalyst
What is the “pot-life”?
The time until curing starts
How does the temperature affect the pot-life?
Increase temperature → more rapid curing process → shorter pot-life
How does vitrification affect the curing?
It abruptly halts the curing (if you want further curing → heat it up to the rubbery phase)
Name five parameters that affect the pot-life and curing of vinyl esters
Catalyst used
Accelerator used
Inhibitor used
Temperature
Age of resin
Mass to be cured
Applied heat
Size and type of mould
Fillers/reinforcements
What is gelation?
Gelation is characteristic for thermosets, and it is of foremost significance
From a processing standpoint, gelation is critical since the polymer does
not flow and is no longer processable beyond this point.
What is Vitrification?
glassy states –> abrupt halt to curing
Describe the curing of epoxy.
- starts with connecting monomers in a liquid state.
- Reaches gelation (does not affect the movement of monomers)
- Reaches vitrification (glassy state)
To cure an epoxy resin a hardener is needed.
What temperature is required when curing epoxy?
Some epoxy systems can be cured even at temperatures as low as 0°C. However, to obtain good mechanical properties it is normally recommended to cure the resin at +20°C and then (if needed) post cure the material at higher temperature.
When curing epoxy, a hardener is required. What does this affect?
Different harderners have different ideal curing temperatures → affects the curing rate.
How is the temperature of curing epoxy determined?
The higher the temperature is of curing epoxy, the faster it cures. The temperature of curing epoxy is determined by the ambient temperature plus the exothermic heat generated by its cure. (ambient temperature + exothermic heat)
What happens when heating epoxy that has not gelled?
will lower its viscosity, allowing the epoxy to run or sag more easily on vertical surfaces.
What can happen when heating epoxy applied to a porous substrate?
heating epoxy applied to a porous substrate (softwood or low-density core material) may cause the substrate to “out-gas” and form bubbles in the epoxy coating. To avoid out-gassing, wait until the epoxy coating has gelled before warming it.
How does incomplete curing effect epoxy?
Lower stiffness
Higher moisture absorption
Reduced chemical resistance
Risk of allergic reaction
Skin, red and swallowed
Stiffness not as high as expected, higher moisture, bad chemical resistance
Name three important substances to look out for when working with thermoset-based composite materials.
Styrene, epoxy, dust, solvents (catalysts, accelerators)
What is important to remember when working with uncured epoxy?
Use suitable gloves!
What is important to remember when working with uncured polyester?
Good ventilation!
How can the amount of styrene in the air be reduced when working with UP?
Add some wax? Places on the top of the material ⇒ reduce the styrene in the air
How can the curing of thermosets be studied?
Spectroscopy Magnetic resonans (NMR) Thermal analysis (DSC) Dielectric measurements Hardness tests Tensile tes
How can the amount of styrene in the air be reduced when working with UP?
Add some wax? Places on the top of the material ⇒ reduce the styrene in the air
How shall waste and spill of uncured resins be taken care of?
Place it in bags
Mark the bags with thermosets
Clean floor etc.
Describe the manufacturing of a plug
In order to make a mould, we make a plug = master model
Wood, plywood, cover it with clay, mill it in order to get the right dimensions, finish and polish surfaces. Paint the plug and add wax to the plug in order to not get stuck
Describe the manufacturing of a mould when you have a plug.
- Apply a gelcoat
- Apply laminate layer of glass fibre (CSM) + temperature resistant esin
- Apply structural laminate layer (in steps to avoid shrinkage) CSM or spray- up of glass fiber and polyester
- Add stiffeners: built up by fibre-reinforced plastics
Describe a good way of de-moulding a composite motorboat hull
Start the de-moulding process by trimming the edges.
Then release the edges by the use of wooden or plastic wedges.
Apply compressed air carefully along the released edges.
Remove the component!
Store the component appropriately until it has fully cured
What different manufacturing methods are Fosieplast using?
Hand lay-up (poor mechanical properties) and Vacuum Injection Moulding (large components)
Name 5 advantages with vacuum injection moulding compared to hand lay-up
better mechanical properties (less voids) better working environment faster process less material needed (spill) cheaper
Why are different types of flow media used in vacuum injection moulding
to be able to impregnate a long piece
to speed the process up for large components
Describe the structure for three different types of flow media
Surface medium
allows very fast distribution of large quantities of resin,
and provides good control over the flow front
Core channels
most effective on flat surfaces,
and a very effective, waste-free way to infuse parts
Interlaminar medium
highly porous
layer in the laminate, such as a continuous roving material or a nonwoven
breeder-like material
What is a “skin coat”?
Normally, a skin coat consists of a few layers of CSM with a high quality, low-shrink resin.
flat shiny surface (not fibers), made from hand lay-up → prevent fiber print-through
What is a barrier coat?
similar… but made out of a resin layer.
more effective than skin coat
What different types of manufacturing methods are “Composite Design” using?
prepreg (low voids, high fibres)
Pros with prepreg?
high fibre content
low void content → good mech. properties
Cons with prepreg?
touch when not cured: allergic reactions
expensive