Institute of Chemical Technology,

Mumbai
University of Mumbai

 Presented By
 Dr. S.T.Mhaske

26/6/2008 Department of Polymer Technology & Engineering

Company
LOGO

We live in
PLASTIC AGE

26/6/2008 Department of Polymer Technology & Engineering

Company
LOGO

Imagine life
without
plastics

26/6/2008 Department of Polymer Technology & Engineering

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LOGO Thermosets

Plastics
Thermoplastics

Rubber

Polymer Fibers

Adhesives

Inks
Surface Coating
Paints
26/6/2008 Department of Polymer Technology & Engineering
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LOGO

Polymer
 Poly - Many

 Mer - Substance

Polyclinic, Polytechnic etc.

26/6/2008 Department of Polymer Technology & Engineering

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LOGO

Chemical compounds formed when many small

chemical units (monomers) combine to form large
molecules with a regular repeating structure.

Monomer Polymer
26/6/2008 Department of Polymer Technology & Engineering
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LOGO

Monomer – Starting Material Polymer

 Monomer Polymer
 Ethylene Polyethylene (PE)
 Propylene Polypropylene (PP)
 Vinyl Chloride Polyvinylchloride (PVC)
 Styrene Polystyrene (PS)

26/6/2008 Department of Polymer Technology & Engineering

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LOGO Polymers – Size of
Methane
Molecules
= CH ➪ Gas 4

Octane = C8H18 ➪ Liquid

Paraffin Wax = C50H102 ➪ Solid

Polyethylene = C2000H4002 ➪
Polymer
26/6/2008 Department of Polymer Technology & Engineering
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LOGO

 Polymers are formed due to “functionality”

of a monomer.

 Minimum of two “functionality” is needed

for forming polymers.

26/6/2008 Department of Polymer Technology & Engineering

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LOGO

 Polymers are i) Linear

ii) Branched

Linear

Branched

26/6/2008 Department of Polymer Technology & Engineering

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Thermal Behaviour of
LOGO
polymers
 Thermoplastics….. The material can be
heated, melted, shaped on cooling
repeatedly. Like a wax candle, polyethylene,
nylon etc.

 Thermosets………. The material can be

shaped only once. e.g. Egg yolk, Araldite,
moulding powder, crosslinked rubber etc.

26/6/2008 Department of Polymer Technology & Engineering

Company TYPICAL
LOGO
CHARACTERISTICS OF
POLYMERS
 MW & MWD
 Amorphous / Crystalline phases
 Glass transition temperature
 Variation of properties with molecular
weight.
 Selecting the “Grades”

26/6/2008 Department of Polymer Technology & Engineering

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LOGO

 n is an average number
 If n is higher, molecular weight is higher.
Properties are different.
 n is small, polymer is waxy
 n is higher, polymer is hard, solid like..
 The different values of n, yield different
grades…… extrusion grade, film grade,
fibre grade etc.
 Molecular weight decides the properties
26/6/2008 Department of Polymer Technology & Engineering
 The properties of polymer
Company
LOGO are related to its
MOLECULAR WEIGHT ( or
size
As aof
resultchain )
of the polymerization process:
Almost all polymers contain
a Range of Molecular Sizes.

log Number of Molecules

log Molecular Size (Weight)

26/6/2008 Department of Polymer Technology & Engineering
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LOGO

 Narrow molecular weight distribution….

more suitable for fibre spinning, films.

 Broad molecular weight distribution……

more suitable for injection moulding.

26/6/2008 Department of Polymer Technology & Engineering

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LOGO

 The polymers are “solid” but not

crystalline.
e.g. glass is an amorphous material.

 Due to long chains, the mobility of each

chain is limited. While cooling, before
chains occupy well defined crystalline
shape, they lose the mobility and “freeze”,
forming an amorphous state.
26/6/2008 Department of Polymer Technology & Engineering
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LOGO

Semi-Crystalline
Amorphous
Contains both crystalline
No polymer structure.
(ordered)and amorphous
Examples: Poly Vinyl Chloride polymer.
Polystyrene
Polycarbonate Examples: Polyethylene
PMMA Polypropylene
PET
Polyamides (nylon)

26/6/2008 Department of Polymer Technology & Engineering

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LOGO Introduction
 Why Composites are
Important
 Composites can be very strong and stiff, yet very light in
weight, so ratios of strength‑to‑weight and
stiffness‑to‑weight are several times greater than steel or
aluminum
 Toughness is often greater too
 Composites can be designed that do not corrode like steel
 Possible to achieve combinations of properties not attainable
with metals, ceramics, or polymers alone

26/6/2008 Department of Polymer Technology & Engineering

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LOGO Objectives

Define the composites and difference
types of composites.
 Describe the various manufacturing
methods used to produce composites.

List the different reinforcing materials
used in composites.

26/6/2008 Department of Polymer Technology & Engineering

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LOGO

 Composite definition

 A composite is a material comprised of two or more

physically distinct materials with at least one material
providing reinforcing properties on strength and
modulus.

26/6/2008 Department of Polymer Technology & Engineering

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LOGO
Types of
Matrix Metal
Composites Ceramic Polymer
phase/Reinforcement
Phase

Metal Powder metallurgy Cermets (ceramic- Brake pads

parts – combining metal composite)
immiscible metals
Ceramic Cermets, TiC, TiCN SiC reinforced Al2O3 Fiberglass
Cemented carbides – Tool materials
used in tools
Fiber-reinforced metals

Polymer Kevlar fibers in an

epoxy matrix

Elemental (Carbon, Fiber reinforced metals Rubber with carbon

Boron, etc.) Auto parts (tires)
aerospace Boron, Carbon
reinforced plastics

MMC’s CMC’s PMC’s

Metal Matrix Composites Ceramic Matrix Comp’s. Polymer Matrix Comp’s
26/6/2008 Department of Polymer Technology & Engineering
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Classification based on
LOGO
Matrices
Composite
materials

Matrices

Polymer Metal Matrix Ceramic Matrix

Matrix Composites Composites
Composites MMC) (CMC)
(PMC)

Thermose Thermoplast Rubber

t ic

26/6/2008 Department of Polymer Technology & Engineering

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Automotive Plastics and
LOGO
Composites Use
Exterior Composite Panels
 Doors
 Sheet Molded Compound (SMC): Camaro,
Firebird and Corvette
 Resin Transfer Molding (RTM): Viper
 Hoods
 Sheet Molded Compound (SMC): Camaro,
Firebird, Corvette, Ford trucks
 Resin Transfer Molding (RTM): Viper, Heavy
duty trucks)
26/6/2008 Department of Polymer Technology & Engineering
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LOGO

 Bumper Beams
 Glass Mat Thermoplastic (GMT): Camaro,
Firebird, Venture, Transport,
Interior

Floor pan
 Resin Transfer Molding (RTM): Corvette
Engine

Valve covers, intake manifolds, fluid containers, etc.

26/6/2008 Department of Polymer Technology & Engineering

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Automotive Plastics and
LOGO
Composites Use

SMC
Sheet Molding
Compound
SMC
Sheet Molding
Compound
26/6/2008 Department of Polymer Technology & Engineering
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LOGO FORD FOCUS /C-MAX Front
window dash panel

Part weight: 1.4 kg

26/6/2008 Department of Polymer Technology & Engineering

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LOGO Interior Applications

26/6/2008 Department of Polymer Technology & Engineering

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LOGO Exterior Applications

26/6/2008 Department of Polymer Technology & Engineering

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LOGO Composite Survey

C o m p o s it e s

P a r t ic le - r e in fo r c e d F ib e r - r e in fo r c e d S tru c tu ra l

L a rg e - D is p e r s io n - C o n t in u o u s D is c o n t in u o u s L a m in a t e s S a n d w ic h
p a r t ic le s tre n g th e n e d ( a lig n e d ) (s h o rt) p a n e ls

A lig n e d R a n d o m ly
o r ie n t e d

26/6/2008 Department of Polymer Technology & Engineering

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LOGO Reinforcing Phase
 Fibres
 Particles and Flakes
 Infiltrated Phase
 Interface

26/6/2008 Department of Polymer Technology & Engineering

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LOGO Materials for Fibers
 Fiber materials in fiber‑reinforced
composites:

Glass – most widely used filament

Carbon – high elastic modulus

Boron – very high elastic modulus

Polymers - Kevlar

Ceramics – SiC and Al2O3

Metals - steel
 The most important commercial use of fibers
is in polymer composites
26/6/2008 Department of Polymer Technology & Engineering
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LOGO

Fiber Glass

Graphite Fiber

Kevlar Fiber

Kevlar/Carbon Hybrid
26/6/2008 Department of Polymer Technology & Engineering
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How does fiber
LOGO
reinforcement work ?

26/6/2008 Department of Polymer Technology & Engineering

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Polymer Matrix
LOGO
Composites
 Fibre reinforced polymers (FRPs)
 Polymer matrix reinforced with fibres
 Matrix is typically TP (polyester or epoxy)
and TS such as nylons, PVC,
polycarbonates and polystyrene
 Fibres are typically glass, carbon and
Kevlar 49 (up to 50%)

26/6/2008 Department of Polymer Technology & Engineering

Company
LOGO Polymer Modifier

Dry Blending

Compounding
(Twin screw extruder)

Pelletization

Injection molding

Mechanical Rheological
Properties
Properties

Morphology Thermal

Properties
26/6/2008 Department of Polymer Technology & Engineering
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LOGO Characterization

26/6/2008 Department of Polymer Technology & Engineering

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LOGO

Mechanical Properties

Tensile strength Flexural Properties Motorized Notch

LR50K,Lloyd LR50K,Lloyd Cutting Machine Ray
Inst.(U.K.) Inst.(U.K.) Ran (U.K.)

ASTM Impact Strength

ASTM
D790 M Avery Denison,
D638-M91
(U.K)

ASTM
Cross head jaw Cross head jaw D256
speed was 50 speed was 2.8
mm/min mm/min

2.7J striker with striking

velocity of 3.46 m/s

26/6/2008 Department of Polymer Technology & Engineering

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Processing of
LOGO
Composites
 Open Mold processes
 Hand lay-up
 Spray-up

Vacuum bag, pressure bag, autoclave

Filament winding
 Centrifugal casting
 Closed Mold Processes

Compression molding

Injection Molding [high pressure]
 Resin Transfer Molding (RTM), Structural Reaction Injection
Molding (SRIM) [low pressure]
 Pultrusion
26/6/2008 Department of Polymer Technology & Engineering
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Reaction Injection
LOGO
Molding (RIM)
Fiber preform is placed into mold.
Polyol and Isocyanate liquids are injected into a closed mold and reacted to
form a urethane.

26/6/2008 Department of Polymer Technology & Engineering

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LOGO Hand Lay-up

Resins are impregnated by hand into fibres which are in the

form of woven, knitted, stitched or bonded fabrics.

This is usually accomplished by rollers or brushes

26/6/2008 Department of Polymer Technology & Engineering

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LOGO Filament Winding

This process is primarily used for hollow, generally

circular or oval sectioned components, such as pipes and
tanks.

26/6/2008 Department of Polymer Technology & Engineering

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Sheet Molding
LOGO
Compound (SMC)
 Chopped glass fiber added to polyester resin mixture

26/6/2008 Department of Polymer Technology & Engineering

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LOGO Pultrusion

26/6/2008 Department of Polymer Technology & Engineering

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LOGO

26/6/2008 Department of Polymer Technology & Engineering

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LOGO Compression Molding
 Compression molding was specifically developed for
replacement of metal components with composite
parts.

 The molding process can be carried out with either

thermosets or thermoplastics.

 Compression molding is the most common method

of processing thermosets.

26/6/2008 Department of Polymer Technology & Engineering

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Compression molding
LOGO
process

26/6/2008 Department of Polymer Technology & Engineering

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LOGO Resin Transfer Molding
 In the RTM process, preform which is inserted into a
matched die mold.

 The heated mold is closed and the liquid resin is injected

 The part is cured in mold.

 The mold is opened and part is removed from mold.

26/6/2008 Department of Polymer Technology & Engineering

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Injection Molding
LOGO
Glass Reinforced
Composites
 Plastic pellets with glass fibers are melted in
screw, injected into a cold mold, and then ejected.

26/6/2008 Department of Polymer Technology & Engineering

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Applications Of PP / GMT
LOGO
Composites
Passenger
car bucket
seat

Bumper
backup
beam

Ford Taurus
station wagon
load floor

Typical office
furniture

26/6/2008 Department of Polymer Technology & Engineering

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LOGO Recreational Plastics
and Composites Use
 Snow Equipment

skis, snow boards, snow
mobiles, etc.
 Water Sports Equipment

water skis, water crafts,
snorkel equipment, fishing
gear

diving equipment
 Land Sports Equipment
 shoes, roller blades, skate
boards, tennis, golf
 Air Sports Equipment
 plane kits

26/6/2008 Department of Polymer Technology & Engineering

Company Long-Fiber
LOGO
Thermoplastics
In Auto
Long Fiber PP enhances surface
Applications
finish & strength in the base of air Long glass fiber PP door surrounds
compressor for automotives

26/6/2008 Department of Polymer Technology & Engineering

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LOGO BENEFITS - SUMMARY

 LIGHT WEIGHT
 HIGH STRENGTH to WEIGHT RATIO
 COMPLEX PART GEOMETRY
 PARTS CONSOLIDATION
 DESIGN FLEXIBILITY
 LOW SPECIFIC GRAVITY
 LOW THERMAL CONDUCTIVITY
 HIGH DIELECTRIC STRENGTH

26/6/2008 Department of Polymer Technology & Engineering

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LOGO

THANK YOU

26/6/2008 Department of Polymer Technology & Engineering