POLYMER COMPOSITE

What is Composites?
 Combination of 2 or more materials
 Each of the materials must exist more than
5%
 Presence of interphase
 The properties shown by the composite
materials are differed from the initial
materials
 Can be produced by various processing
techniques
 Constituents of composite materials
. Matrix phase
ontinuous phase, the primary phase.
t holds the dispersed phase and shares a load with it.

. Dispersed (reinforcing) phase

he second phase (or phases) is imbedded in the matrix in a
ontinuous/discontinuous form.
Dispersed phase is usually stronger than the matrix, therefore it is sometimes
alled reinforcing phase.

. Interface
one across which matrix and reinforcing phases interact (chemical, physical,
mechanical)
Matrix: Function

however the distribution of loads depends on the interfacial bondings

Reinforcement: Function
Reinforcement can be in the form
of:
 Continuous fiber
 Organic fiber- i.e. Kevlar, polyethylene
 Inorganic fiber- i.e. glass, alumina, carbon
 Natural fiber- i.e. asbestos, jute, silk
 Short fiber
 whiskers
 Particle
 Wire
Interface: Function
 To transfer the stress from matrix to
reinforcement

Sometimes surface treatment is carried out

to achieve the required bonding to the
matrix
 Characteristics
Characteristicsof
ofdispersed
dispersedphase
phasethat
thatmight
might
influence
influencethe
theproperties
propertiesof
ofcomposites
composites

a) Concentration (b) size (c) shape (d) distribution (e)

orientation
Classification
Classification of
of composites
composites
Examples of composites

a) Particulate & random

b) Discontinuous fibers & unidirectional
c) Discontinuous fibers & random
d) Continuous fibers & unidirectional
Classification based on Matrices
Composite
materials

Matrices

Polymer Matrix Metal Matrix Ceramic Matrix

Composites (PMC) Composites MMC) Composites (CMC)

Thermoset Thermoplastic Rubber

What is Hybrid composites?
What are the advantages of
hybrid composites?
 Widely used- ease of processing & lightweight
 Composite materials in the Boeing 757
(courtesy of Boeing Commercial Airplane Group)
Properties of composites depend
on
 Amount of phase
- Amount/proportion (can be expressed in
weight fraction (Wf) or volume fraction
(Vf))of phases strongly influence the
properties of composite materials.
Xc = Xf Vf + Xm (1 - Vf ) - Rule of Mixture
Xc = Properties of composites
Xf = Properties of fiber
Xm= Properties of matrix
Voids
 Free volume
 Gas emission leads to voids in the
final product
 In composites- Voids exist in the
matrix, interface and in between fiber
& fiber
 Voids create stress concentration
points- influence the properties of the
composites
 Geometry of dispersed phase
(particle size, distribution,
orientation)
 Shape of dispersed phase (particle- spherical or
irregular, flaky, whiskers, etc)
 Particle/fiber size ( fiber- short, long,
continuous); particle (nano or micron size)
 Orientation of fiber/particle (unidirection, bi-
directions, many directions)- influence isotropic
dan an-isotropic properties
 Dictribution of dispersed phase
(homogenus/uniform, inhomogenus)
Processing technique and
parameters
 Influence final product, selection of correct
raw materials, void content, etc
Glass Fiber
The types of glass used are as follows:
 E-Glass – the most popular and inexpensive glass fibers. The
designation letter “E” means “electrical” (E-Glass is excellent
insulator). The composition of E-glass ranges from 52-56%
SiO2, 12-16% A1203, 16-25% CaO, and 8-13% B203
 S-Glass – stronger than E-Glass fibers (the letter “S” means
strength). High-strength glass is generally known as S-type
glass in the United States, R-glass in Europe and T-glass in
Japan. S-Glass is used in military applications and in
aerospace. S-Glass consists of silica (SiO2), magnesia (MgO),
alumina (Al2O3).
 C-Glass – corrosion and chemical resistant glass fibers. To
protect against water erosion, a moisture-resistant coating such
as a silane compound is coated onto the fibers during
manufacturing. Adding resin during composite formation
provides additional protection. C-Glass fibers are used for
manufacturing storage tanks, pipes and other chemical
resistant equipment.
Glass Fiber
 Fiberglasses (Glass fibers reinforced polymer matrix
composites) are characterized by the following
properties:
 High strength-to-weight ratio;
 High modulus of elasticity-to-weight ratio;
 Good corrosion resistance;
 Good insulating properties;
 Low thermal resistance (as compared to metals and
ceramics).
 Fiberglass materials are used for manufacturing:
boat hulls and marine structures, automobile and
truck body panels, pressure vessels, aircraft wings
and fuselage sections, housings for radar systems,
swimming pools, welding helmets, roofs, pipes.
Carbon Fiber
 The types of carbon fibers are as
follows:
 UHM (ultra high modulus). Modulus of
elasticity > 65400 ksi (450GPa).
 HM (high modulus). Modulus of
elasticity is in the range 51000-65400
ksi (350-450GPa).
 IM (intermediate modulus). Modulus of
elasticity is in the range 29000-51000
ksi (200-350GPa).
 HT (high tensile, low modulus). Tensile
strength > 436 ksi (3 GPa), modulus of
elasticity < 14500 ksi (100 GPa).
 SHT (super high tensile). Tensile
strength > 650 ksi (4.5GPa).
Carbon Fiber
 Carbon Fiber Reinforced Polymers (CFRP) are characterized
by the following properties:
 Light weight;
 High strength-to-weight ratio;
 Very High modulus elasticity-to-weight ratio;
 High Fatigue strength;
 Good corrosion resistance;
 Very low coefficient of thermal expansion;
 Low impact resistance;
 High electric conductivity;
 High cost.
 Carbon Fiber Reinforced Polymers (CFRP) are used for
manufacturing: automotive marine and aerospace parts, sport
goods (golf clubs, skis, tennis racquets, fishing rods), bicycle
frames.
Kevlar Fiber
 Kevlar is the trade name (registered by DuPont Co.)
of aramid (poly-para-phenylene terephthalamide)
fibers.
 Kevlar fibers were originally developed as a
replacement of steel in automotive tires.
 Kevlar filaments are produced by extrusion of the
precursor through a spinnert. Extrusion imparts
anisotropy (increased strength in the lengthwise
direction) to the filaments.
 Kevlar may protect carbon fibers and improve their
properties: hybrid fabric (Kevlar + Carbon fibers)
combines very high tensile strength with high impact
and abrasion resistance.
Kevlar Fiber
 Kevlar fibers possess the following properties:
 High tensile strength (five times stronger per
weight unite than steel);
 High modulus of elasticity;
 Very low elongation up to breaking point;
 Low weight;
 High chemical inertness;
 Very low coefficient of thermal expansion;
 High Fracture Toughness (impact resistance);
 High cut resistance;
 Textile processibility;
 Flame resistance.
 The disadvantages of Kevlar are: ability to absorb
moisture, difficulties in cutting, low compressive
strength.
Kevlar Fiber (poly-paraphenylene
terephthalamide)
 There are several modifications of Kevlar,
developed for various applications:
 Kevlar 29 – high strength (520000 psi/3600 MPa),
low density (90 lb/ft³/1440 kg/m³) fibers used for
manufacturing bullet-proof vests, composite armor
reinforcement, helmets, ropes, cables, asbestos
replacing parts.
 Kevlar 49 – high modulus (19000 ksi/131 GPa),
high strength (550000 psi/3800 MPa), low density
(90 lb/ft³/1440 kg/m³) fibers used in aerospace,
automotive and marine applications.
 Kevlar 149 – ultra high modulus (27000 ksi/186
GPa), high strength (490000 psi/3400 MPa), low
density (92 lb/ft³/1470 kg/m³) highly crystalline
fibers used as reinforcing dispersed phase for
composite aircraft components.
Reasons for the use of polymeric
materials as matrices in composites
 i. The mechanical properties of polymers
are inadequate for structural purposes,
hence benefits are gained by reinforcing the
polymers
 Processing of PMCs need not involve high
pressure and high temperature
 The equipment required for PMCs are much
simpler
Disadvantages of PMC
 Low maximum working
temperature
 High coefficient of thermal
expansion- dimensional
instability
 Sensitivity to radiation and
moisture
Classification of Polymer
Matrices
 1. Thermoset
 2. Thermoplastic- crystalline &
amorphous
 3. Rubber
Thermoset
 Thermoset materials are usually liquid or malleable prior to curing,
and designed to be molded into their final form
 has the property of undergoing a chemical reaction by the action
of heat, catalyst, ultraviolet light, etc., to become a relatively
insoluble and infusible substance.
 They develop a well-bonded three-dimensional structure upon
curing. Once hardened or cross-linked, they will decompose
rather than melt.
 A thermoset material cannot be melted and re-shaped after it is
cured.
 Thermoset materials are generally stronger than thermoplastic
materials due to this 3-D network of bonds, and are also better
suited to high-temperature applications up to the decomposition
temperature of the material.
 Thermoplastic
 is a plastic that melts to a liquid when heated and
freezes to a brittle, very glassy state when cooled
sufficiently.
 Most thermoplastics are high molecular weight
polymers whose chains associate through weak van
der Waals forces (polyethylene); stronger dipole-
dipole interactions and hydrogen bonding (nylon); or
even stacking of aromatic rings (polystyrene).
 The bondings are easily broken by the cobined action
of thermal activation and applied stress, that’s why
thermoplastics flow at elevated temperature
 unlike thermosetting polymers, thermoplastic can be
remelted and remolded.
 Thermoplastics can go through
melting/freezing cycles repeatedly and the
fact that they can be reshaped upon
reheating gives them their name
 Some thermoplastics normally do not
crystallize: they are termed "amorphous"
plastics and are useful at temperatures
below the Tg. They are frequently used in
applications where clarity is important.
Some typical examples of amorphous
thermoplastics are PMMA, PS and PC.
 Generally, amorphous thermoplastics are
less chemically resistant
 Depends on the structure of the
thermoplastics, some of the polymeric structure
can be folded to form crystalline regions, will
crystallize to a certain extent and are called
"semi-crystalline" for this reason.
 Typical semi-crystalline thermoplastics are PE,
PP, PBT and PET.
 Semi-crystalline thermoplastics are more
resistant to solvents and other chemicals. If the
crystallites are larger than the wavelength of
light, the thermoplastic is hazy or opaque.
 Why HDPE exhibits higher cystallinity than
LDPE?
 Comparison of typical ranges of
property values for thermoset and
thermoplastics

 Properties t/set t/plastic

 Young’s Modulus (GPa)1.3-6.0 1.0-4.8
 Tensile strength(MPa) 20-180 40-190
 Max service temp.(ºC) 50-450 25-230
 Fracture toughness,KIc 0.5-1.0 1.5-6.0
(MPa1/2)
Thermoplastics are expected to
receive attention compared to
thermoset due to:

 Ease of processing
 Can be recycled
 No specific storage
 Good fracture modulus
Rubber
 Common characteristics;
 Large elastic elongation (i.e. 200%)
 Can be stretched and then immediately return to
their original length when the load was released
 Elastomers are sometimes called rubber or rubbery
materials
 The term elastomer is often used interchangeably with
the term rubber
 Natural rubber is obtained from latex from Hevea
Brasiliensis tree which consists of 98% poliisoprena
 Synthetic rubber is commonly produced from
butadiene, spt styrene-butadiene (SBR) dan nitrile-
butadiene (NBR)
 To achieve properties suitable for
structural purposed, most rubbers
have to be vulcanized; the long
chain rubber have to be crosslinked
 The crosslinking agent in
vulcanization is commonly sulphur,
and the stiffness and strength
increases with the number of
crosslinks
POLYMER Applicatios
 Introduction
Introduction
 Most of polymers need to add with specific ingredients to obtain
desirable properties.
 Additives were used:
 To improved or modify the mechanical, chemical, and physical
properties
 To prevent degradation (both during fabrication and in service)
 To reduce materials costs
 To improve the processability

 Each of the additives in formulation has specific functions either

during processing or end products applications
 Typical additives include
 filler materials,
 Plasticizer
 stabilizers,
 colorants
 flame retardants.
 Fillers
Fillers
 Fillers normally add in polymeric materials for economical or
technical
 Filler materials are most often added to polymers to
improve tensile and compression strengths, abrasion
resistance, toughness, dimensional and thermal stability and
other properties.
 Materials used as particulate fillers  include wood flour
(finely powdered sawdust), silica flour and sand, glass, clay,
talc, limestone, and even some synthetic polymers.
 Particle sizes range all the way from 10 nm to macroscopic
dimensions
 Because these inexpensive materials replace some volume
of the more expensive polymer, the cost of the final
product is reduced.
 Plasticizers
Plasticizers
 Can be in liquid, half solid or solid form.
 It must be compatible with the polymeric
materials and other compounding ingredients 
incompatibility will results in poor processing
properties.
 Plasticizer were used for:
1. ‘extender’ (large amount >20 pphr) to make the
end products cheaper
2. Processing aid (small amount 2-5 pphr) to
make the processing easier

3. Modifier  to modifies some polymeric

properties.
 The aid of additives called plasticizers can :
 improved the flexibility, ductility, and toughness

 produces reductions in hardness and stiffness

 lowers the glass transition temperature  at

ambient conditions the polymers may be used
in applications requiring some degree of
flexibility and ductility.

 These applications include thin sheets or

films, tubing, raincoats, and curtains.
 Stabilizers
Stabilizers
 Some polymeric materials under normal environmental
conditions are subject rapid deterioration in mechanical
properties.

 Most often this deterioration is a result of exposure to light

 in particular ultraviolet radiation and oxidation
 Ultraviolet radiation 
 causes a severance of some of the covalent bonds along the
molecular chain
 also result in some crosslinking.

 Oxidation deterioration is a consequence of the chemical

interaction between oxygen atoms and the polymer
molecules.

 Additives that counteract these deteriorative processes are

called stabilizers.
 Colorants
Colorants
 Colorants impart a specific color to a polymer
 They may be added in the form of:
 dyes
 The molecules in a dye actually dissolve and become part
of the molecular structure of the polymer.

 pigments.
 Pigments are filler materials that do not dissolve  but
remain as a separate phase;
 have a small particle size, are transparent, and have a
refractive index near to that of the parent polymer.
 Others may impart opacity as well as color to the polymer.
 Flame
Flame retardants
retardants
 The flammability of polymeric materials is a major concern,
especially in the manufacture of textiles and children's toys.

 Most polymers are flammable in their pure form  exceptions

include those containing significant contents of chlorine and/or
fluorine such as polyvinyl chloride (PVC) and
polytetrafluoroethylene (PTFE).

 The flammability resistance of the remaining combustible

polymers enhanced by additives called flame retardants.

 These retardants may function by

 interfering with the combustion process through the gas
phase, or
 by initiating a chemical reaction that causes a cooling of the
combustion region and a termination of burning.
 Special
Special purpose
purpose additives
additives
Additives Function
Blowing agents Gas generating chemicals that are necessary for
manufacturing sponge or micro porous products
Odorants Strongly scented substances added in small amounts
that are capable of imparting a pleasant scent
Antistatic agents Added to reduce the accumulated of dust or dirt on
surface and also to minimize possibility of sparking
resulting from the discharge of accumulated static
electricity
Retarders Substances that used to reduce the tendency of
rubber mix to scorch  avoid premature
vulcanization during processing
Antioxidants Protects products from oxidation of heat

Antiflex cracking Agents that retard cracking caused by cyclic

deformations
 Example
Example of
of the
the exams
exams question
question

 What is the function of additives in

polymeric materials?

 Discuss the used of fillers as one of

polymer compounding ingredients.
 EBB 220/3
MISCELLANEOUS
APPLICATIONS

DR AZURA A.RASHID
Room 2.19
School of Materials And Mineral Resources Engineering,
Universiti Sains Malaysia, 14300 Nibong Tebal, P. Pinang
Malaysia
 Coating
Coating
 Coating are frequently applied to the surface
of materials to serve one or more of the
following function:

1. to protect the item from the environment

that may produce corrosive or deteriorative
reactions;

2. to improve the item's appearance

3. to provide electrical insulation.

 Many of the ingredients in coating
materials are polymers  with majority
are organic in origin

 These organic coatings fall into several

different classifications:
 paint,
 varnish,
 enamel,
 lacquer, and
 shellac :
 Adhesives
Adhesives
 An adhesive  substance used to join together the surfaces of
two solid material (termed "adherends") to produce a joint with a
high shear strength
 Adhesives may come from either natural or synthetic sources.
 Some modern adhesives are extremely strong, and becoming
increasingly important in modern construction and industry
 The bond forces between the adhesive and adherend surfaces
are electrostatic similar to the secondary bonding forces
between the molecular chains in thermoplastic polymers
 A strong joint may be produced if the adhesive layer is thin and
continuous.
 If a good joint is formed, the adherend material may fracture or
rupture before the adhesive.
 Polymeric materials that fall within the
classifications of thermoplastics, them setting
resins, elastomeric compounds, and natural
adhesives (animal glue, cast starch, and resin)
may serve adhesive functions.
 Polymer adhesives may be used to join a large
variety of material combinations: metal-metal,
metal-plastic, metal-ceramic, and so on.
 The primary drawback is the service
temperature limitation.
 Organic polymers maintain their mechanical
integrity only at relatively low temperatures,
and strength decreases rapidly with increasing
temperature.
 Some
Some categories
categories of
of adhesives
adhesives
 Natural adhesives
 Adhesives based on vegetable (natural resin), food (animal hide and
skin), and mineral sources (inorganic materials).
 Synthetic adhesives
 Adhesives based on elastomers, thermoplastic, and thermosetting
adhesives.
 Drying adhesives
 These adhesives are a mixture of ingredients  polymer dissolved in a
solvent e.g. glues and rubber cements
 As the solvent evaporates  the adhesive hardens and they will adhere
to different materials to greater or lesser degrees.
 These adhesives are typically weak and are used for household
applications. Some intended for small children are now made non-toxic.
 Hot adhesives (thermoplastic adhesives)
 Also known as "hot melt" adhesives
 they are applied hot and simply allowed to harden as they cool.
 These adhesives have become popular for crafts because of their ease
of use and the wide range of common materials to which they can
adhere.
 Adhesives
Adhesives failure
failure
 Adhesives may fail in one of two ways:
1. Adhesive failure is the failure of the adhesive to stick or bond with
the material to be adhered (also known as the substrate or
adherend).
2. Cohesive failure is structural failure of the adhesive. Adhesive
remains on both substrate surfaces, but the two items separate.
 Two substrates can also separate through structural failure of one of
the substrates 
 this is not a failure of the adhesive. In this case the adhesive remains
intact and is still bonded to one substrate and the remnants of the other.
 For example,
 when one removes a price label, adhesive usually remains on the label
and the surface  this is cohesive failure.
 If, however, a layer of paper remains stuck to the surface  the
adhesive has not failed.
 when someone tries to pull apart oreo cookies with the filling all on one
side. The goal is an adhesive failure, rather than a cohesive failure.
 Films
Films
 Polymeric materials have found widespread use the form
of thin films.
 Films having thicknesses between 0.001-0.0005 in
(0.025 -0.125 mm)
 Used extensively as
 bags for packaging food products and other merchandise,
 as textile products, and a host of other uses.
 Important characteristics of the materials produced and
used as films include:
 Low density,
 high degree of flexibility,
 high tensile and tear strengths,
 resistance attack by moisture and other chemicals,
 low permeability to some gases, especially water vapor.
 Some of the polymers that meet these criteria and are
manufactured in film form are:
 polyethylene,
 polypropylene,
 cellophane, and
 cellulose etate.
 There are several forming methods:
 simply extruded through a thin die slit followed by a rolling
operation that serves to reduce thickness and improve strength.
 Blown moulding
 continuous tubing is extruded through an annular die; and
maintaining a controlled positive gas pressure inside the
tube,
 wall thickness may be continuously reduced( to produce a
thin cylindrical film, which may be cut and laid flat.
 Some of the newer films  produce using co extrusion that is,
multi layers of more than one polymer type are extruded
simultaneously.
 Foams
Foams
 Very porous plastic materials  produced in a
process called foaming
 Both thermoplastic and thermosetting materials
may be foamed by  including in the batch a
blowing agent
 upon heating decomposes with the liberation of a
gas.
 gas bubbles are generated throughout the now-fluid
mass remain as pores up cooling and give rise to
a sponge-like structure.
 The same effect is produced bubbling an inert
gas through a material while it is in a molten
state.
 Some of commonly foamed polymers are :
 polyurethane,
 rubber,
 polystyrene, and
 polyvinyl chloride.

 Foams are commonly used as:

 cushions in automobiles and furniture
 in packaging and
 thermal insulation.
 Example
Example of
of the
the exams
exams question
question

 Discuss two of the various applications of

polymeric materials.

 What are the polymer characteristic to

produced a film?