Advanced-Materials-Manufacturing-2-AMMSlides-Polym

PolymerCompositesManufacturingMECHENG742AdvancedMaterialsManufacturing2.0PolymerCompositeMaterialsWhatdoImeanbythisterm?CompositeMaterial-Formedfromtwoormoredistinctmaterials,takingadvantageoftheindividualpropertiespossessedbyeach.+“Reinforcement”=“Composites”Polymer“Matrix”PolymerCompositesManufacturingMECHENG742AdvancedMaterialsManufacturingNotanewconcept…PolymerCompositesManufacturingMECHENG742AdvancedMaterialsManufacturingAside-therearemanyothermaterialswecanconsiderascomposites!•Metalmatrixcomposites•Ceramicmatrixcomposites•Carbon/Carboncomposites•Naturallyderivedcomposites•Nano-Composites•…manymorepossibilitiesoutthere…Whilewewillfocusonfibre-reinforcedpolymers,someoftheanalysistoolswewilldiscussmaybeapplicabletothesealternativematerials.PolymerCompositesManufacturingMECHENG742AdvancedMaterialsManufacturingWhywillwefocusonPolymerComposites?•Thisismyspecialtyresearcharea...•Thisprovidesanexampleofhowtoaddressmanufacturingofaclassofmaterials…Developknowledgeofthematerials.Developknowledgeofcommonmanufacturingprocesses.Applyappropriateengineeringanalysistoimproveprocessapplication.Youcanapplythislogictoothermaterialsandprocesses.Wewill:PolymerCompositesManufacturingMECHENG742AdvancedMaterialsManufacturingAirTransportationNauticalTransportationExampleProductsPolymerCompositesManufacturingMECHENG742AdvancedMaterialsManufacturingGroundTransportationSpaceProgramsPolymerCompositesManufacturingMECHENG742AdvancedMaterialsManufacturingCivilSportingGoodsPolymerCompositesManufacturingMECHENG742AdvancedMaterialsManufacturingBathroomFurnitureTanksandPressureVesselsPolymerCompositesManufacturingMECHENG742AdvancedMaterialsManufacturingNottheglamorousapplications,buttheyconsumethelargestquantitiesofmaterial.ConstructionMaterialsRoofingshingles:Worldslargestapplicationoffibreglass.PolymerCompositesManufacturingMECHENG742AdvancedMaterialsManufacturingWhileawidevarietyofpolymercompositeproductsexist,thereismuchscopeforimprovingtheproductivityofexistingmanufacturingprocesses,anddevelopmentofnewprocesses.Some“Low-tech”productsareproducedinverylargequantities.E.g.NeedProcessAnalysis&ProcessControlHowever,ingeneralthepotentialforapplicationofpolymercompositestolargemarketsislimitedbyourinabilitytomanufacturelargequantities,withverylowprocesscycletimes.High-techapplicationstypicallyrequirefewpartstobemanufactured,allowingprocesscycletimestobehigh.(Limitedfinancialopportunitieshere).PolymerCompositesManufacturingMECHENG742AdvancedMaterialsManufacturing2.1PerformanceWhatarethebenefitsofferedbyPolymerComposites?•Lowweight•Highspecificstiffness•Highspecificstrength•Abilitytotaylorstructuralpropertiesindifferentdirections(Anisotropy)•Miscellaneousmaterialspecificadvantages…Whendesigningaproduct,weshouldkeepinmind:ManufacturingPerformanceCostsMaterialsPolymerCompositesManufacturingMECHENG742AdvancedMaterialsManufacturingPERFORMANCEWhyMixFibresandMatrix?Whydoweneedthesefibres?Whyimbedtheminamatrix?Whydoweuseaparticularmatrix?Maybe…•Duetogoodmechanicalproperties•Easytomanufacturewith(lowviscosity)•Goodchemicalorheatresistance•Todistributeloadbetweenfibres•Toprotectfragile,brittlefibres•Highstrength,andstiffness•AbilitytobeplacedindirectionofloadingPolymerCompositesManufacturingMECHENG742AdvancedMaterialsManufacturingSpecificMaterialProperties:Whencomparedtootherengineeringmaterials,FRPslookverycompetitivewhenweightisconsidered.TensileStrengths(Mpa)StiffnessE(Gpa)MildSteelAluminiumNylonConcreteRandomFibreFRPAllignedFibreFRP(Load//Fibres)(LoadFibres)SpecificStiffnessE/rSpecificStrengths/rDensityr(kg/m3)7800270011002400180016001600208702.540202003400200802030015005010.970.090.630.424.690.0711.441.420.163.2518.30.61PERFORMANCEPolymerCompositesManufacturingMECHENG742AdvancedMaterialsManufacturingPERFORMANCETailorability:Reinforcingfibrescanbearrangedinmanyarchitectures,placingfibresinthedirectionofloading.IndividualLaminaCompositeLaminatePolymerCompositesManufacturingMECHENG742AdvancedMaterialsManufacturingPERFORMANCEAnalysisofStructuralPerformanceInordertounderstandthebehaviourofacompositelaminate,wenormallyconsidertheindividuallamina.xFibreDirectionye.g.Howdostresscomponentsrelatetofibreorientation,andvolumefraction?PolymerCompositesManufacturingMECHENG742AdvancedMaterialsManufacturing2.2MaterialsBut…•Whichmaterialsshouldweuse?•Whatportionofeachdoweneed?•Howcanweeffectivelymixthem?ExampleFRPProductMatrixFibreCompositescombineMATRIXandREINFORCEMENT.PolymerCompositesManufacturingMECHENG742AdvancedMaterialsManufacturingWewillconsidermatricesformedfrom:Thermosetpolymersresin+catalystMixCureReactionSolidifiedthermosetThermoplasticpolymers,SolidStockorGranulesFinishedProductHeat,Reshape,Mix,etc…MATERIALSPolymerCompositesManufacturingMECHENG742AdvancedMaterialsManufacturingSyntheticornaturalfibrereinforcements.Wewillconsiderreinforcementsformedfrom:Inordertodesignandmanufacturesuccessfulproducts……Wemusthaveabasicknowledgeoftheconstituentmaterials,andhowtheyareprocessed.MATERIALSPolymerCompositesManufacturingMECHENG742AdvancedMaterialsManufac