Công nghệ chế tạo các sản phẩm composites

(Manufacturing of composites)
Lecture 2
Matrices
Nguyễn Bá Kiên
Bộ môn CNVL-Khoa Cơ khí
nbkien@dut.udn.vn

2024
 Contents

• Matrices and Reinforcement

• Basic characteristics

• Functions of matrices

• Types of matrix materials

• Thermoplastic and thermoset

• polymers

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 Basic characteristics
Stacking sequence: Configuration of a laminate that defines ply
composition and the exact sequence of ply orientation and its thickness.

http://web.eng.tau.ac.il/~eliasy/index.php/background/composite-materials

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Classification of engineering polymers.

Balasubramanian, M., 2013. Composite materials and processing. CRC press.

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Matrices and Reinforcement

http://training.pluscomposites.eu/courses/components

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 Functions of matrix
Matrix are vital for the satisfactory performance of the structure:
Ø The matrix material binds the fibers together and transfers the
load to the fibers.It provides rigidity and shape to the structure.
Ø The matrix isolates the fibers so that individual fibers can act
separately.
Ø This stops or slows the propagation of a crack.
Ø The matrix provides a good surface finish quality and aids in the
production of net-shape or near-net-shape parts.
Ø The three broad categories of matrix materials are polymer, metal,
and ceramic matrices.

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 Types of Matrix Materials andTheir
Applications
Ø Polymeric
Ø Metallic
Ø Ceramic

Polymeric
Thermoset:
Epoxies: Principally used in aerospace applications
Unsaturated polyesters,
vinyl esters: Commonly used in automotive, marine, chemical, and electrical
applications
Phenolics: Used in bulk molding compounds
Polyimides: For high-temperature aerospace applications (250°C–400°C)
Cyanate ester —

Thermoplastic
Aliphatic polyamides (polyesters, polycarbonate, polyacetals): Used with
discontinuous fibers in injection- molded articles
Aromatic polyamide
PEEK, polysulfone,
PPS, PEI: Suitable for moderately high temperature applications with
continuous fibers

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 Thermoplastic and thermoset polymers
Thermoset Thermoplastics
Ø Widely used because Ø Composite processing is
composite processing is much difficult because the viscosity
easier with the low-viscosity is high even above the melting
liquid resin temperature
Ø Tackiness (độ dính) is a Ø No tackiness; hence handling
problem/advantage is easy
Ø Relatively high temperatures
Ø Temperature and pressure and pressures are needed for
requirements are less for the processing of
the processing of thermoplastic composites
thermoset composites
Ø Limited storage life
Ø Unlimited storage life
Ø Curing time is lesser
Ø Long curing time because
it involves chemical
reaction
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 Thermoplastic and thermoset polymers
Thermoset Thermoplastics
Ø Post-curing often necessary Ø Post-molding treatment is not
for optimum properties recommended, since shrinkage
may be severe due to
Ø Higher strength and modulus
crystallization
Ø Low tensile elongations
Ø Tougher and less brittle
Ø Better thermal stability
Ø Relatively high tensile elongations
and chemical resistance
Ø Lower thermal stability and
Ø Undergo less creep
chemical
Ø Amorphous
Ø resistance
Ø Post-formability is not
Ø Undergo more creep
possible
Ø May be semicrystalline
Ø Difficult to repair
Ø Post-formability is possible
Ø Recycling is difficult
Ø Ease of repair by solution bonding
Ø Can be recycled easily
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 Thermoplastic and thermoset polymers
Variation of tensile modulus with temperature for
(a) amorphous thermoplastics,
(b) semicrystalline thermoplastics, and
(c) thermosetting polymer.

Mallick, P.K., Fiber-Reinforced Composites, 3rd edn., CRC Press, Boca Raton, FL, 2008, p. 64.

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Thermoplastic and thermoset polymers
Ø Effects of loading rate and temperature on the stress–
strain behavior of polymeric materials.

Mallick, P.K., Fiber-Reinforced Composites, 3rd edn., CRC Press, Boca Raton, FL, 2008, p. 65
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Thermoset resins
Ø Polyester Resins
Ø Epoxy Resins
Ø Cyanate Ester
Resins
Ø Polyimide Resins
Ø Phenolic Resins

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 Polyesters resins
Ø Polyesters are low-cost resin systems and offer excellent
corrosion resistance.
Ø The operating service temperatures for polyesters are lower than
for epoxies.
Ø The resin contains a number of C═C double bonds, through
which cross-links are established.
Ø An ester is the product of reaction between an acid and
alcohol. Similarly unsaturated polyester resin is produced by
reacting unsaturated acid/anhydride with a dihydric alcohol.
Ø Saturated acids are added to modify the chemical
structure between the cross-linking sites.
Ø The diluent also contains C═C double bonds through which
cross- links are established between the neighboring polyester
molecular chains.

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 Polyesters resins
Effect of saturated acid-to-unsaturated acid ratio on the properties of
thermoset polyester resin.

Balasubramanian, M., 2013. Composite materials and processing. CRC press.

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 Polyesters resins
Effect of increasing styrene content on the properties of
thermoset polyester resin.

Mallick, P.K., Fiber-Reinforced Composites, 3rd edn., CRC Press, Boca Raton, FL, 2008, p. 80.

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Epoxy resins
Ø Epoxy is a very versatile resin system, allowing for a broad range
of properties
Ø and processing capabilities.
Ø It exhibits low shrinkage as well as excellent adhesion to a
variety of substrate materials.
Ø Epoxies are the most widely used resin materials and are used
in many applications,from aerospace to sporting goods.
Ø There are varying grades of epoxies with varying levels
of performance to meet different application needs.

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 Epoxy resins
Epoxy resin has the following advantages over other thermoset
resins:
•Absence of volatile matters during curing
• Low curing shrinkage
• Excellent resistance to chemicals and solvents
• Excellent adhesion to a wide variety of fillers,fibers,and other
substances

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 Polyimide resins
Ø Polyimide resins are high-temperature polymers, which can be used up
to 230°C for long periods and up to 315°C for short periods.
Ø The polymers containing – O C – N – C O – groups are known as
polyimides.
Ø Polyimides are classified as thermoplastic polyimides and
thermosetting polyimides.
Ø Thermoplastic polyimides are derived by condensation reaction
between anhydrides or anhydride derivatives and diamines.
Ø Thermosetting polyimides are derived by addition reaction
between unsaturated groups of an amide monomer or oligomer.

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 Phenolic Resins
Ø Phenolics meet FAA (and JAR) requirements for low smoke and
toxicity.
Ø They are used for aircraft interiors, stowbins, and galley walls,
as well as other commercial markets that require low-cost,
flame- resistant,and low smoke products.
Ø Phenolic products have demonstrated their capabilities in
various other applications where:
• High temperature resistance is required.
• Electrical properties are needed.
• Wear resistance is important.
• Good chemical resistance and dimensional stability are
• essential.

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 Thermoplastic Resins
Ø Nylons
Ø Polypropylene (PP)
Ø Polyethylene terephthalate
(PET)
Ø Polyetheretherketone (PEEK)
Ø Polyphenylene Sulfide (PPS)

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 Molecular arrangements
(a) amorphous and
(b) semi-crystalline polymers

Mazumdar, M., 2015. Composites manufacturing Materials, Product, and Process Engineering. CRC press.

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 Nylons
Ø Nylons are used for making intake manifolds,housings, gears,
bearings, bushings, sprockets, etc. Glass-filled and carbon-filled
nylons in pellet form are available for injection molding
purposes.
Ø Nylons are most widely used for injection molding purposes,
but are also available as prepregs with various reinforcements.
Ø Nylons have been used for various pultruded components.
Ø Nylons are also called polyamides.There are several types of
nylon, including nylon 6,nylon 66, nylon 11, etc.,each offering a
variety of mechanical and physical properties.

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 Polypropylene (PP)
Ø Polyolefins are by far the largest class of synthetic polymers
made and used today.
Ø The attractive properties are low cost of production, light
weight, and high chemical resistance.
Ø A wide range of mechanical properties is possible through the
use of copolymerization, blending, and additives.
Ø Polyolefins are the polymers made from
olefins. The density of polyolefins is less than 1.0 g cm−3.
Ø The components made from the polyolefins are always lighter
in weight.
Ø Since they are fully saturated, they have a high degree of chemical
resistance to many of the solvents and liquids.
Ø Moreover, they are highly stable to oxidation.

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 Polyethylene terephthalate (PET)
Ø Polyethylene terephthalate (PET) is generally made from
dimethyl terephthalate and ethylene glycol.
Ø It has a high melting point (~265°C) because of the presence of
aromatic ring. It is highly crystalline and rigid.
Ø This polymer is difficult to process due to the presence of a
large number of para-linked aromatic rings in the molecular chain.
Ø A small amount of dimethyl isophthalate is introduced during
the polymerization reaction, which reduces the crystallinity and
rigidity by forming meta-linkages.
Ø PET is one of the most popular commercial polymers. It has
very good resistance to many chemicals and has good
mechanical strength up to 175°C. PET is widely used to make
textile fibers, films,and containers.

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 Polyphenylene Sulfide
Ø PPS molecules consist of the repeating unit shown in
Figure.

Ø The crystallinity of this polymer is around 85% and the melting

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 Polyetheretherketone (PEEK)
Ø PEEK is a new-generation thermoplastic that offers the
possibility of use at high service temperatures.
Ø Carbon-reinforced PEEK composites (APC-2) have already
demostrated their usefulness in fuselage, satellite parts, and
other aerospace structures; they can be used continuously at
250°C.
Ø The glass transition temperature of PEEK is 143°C and
crystalline melting temperature is ~336°C.
Ø PEEK/carbon thermoplastic composites (APC-2, aromatic
polymer composites) have generated significant interest among
researchers and in the aircraft industry because of their greater
damage tolerance, better solvent resistance, and high-
temperature usage.
Ø PEEK has the advantage of almost 10 times lower water
absorption than epoxies.
Ø The water absorption of PEEK is 0.5% at room temperature,
whereas aerospace-grade epoxies have 4 to 5% water absorption.
Ø The drawback of PEEK-based composites is that the materials
cost is very high,more than $50.00/lb.

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 Assignment
Take a daily use thermoset and thermoplastic
product and list down their relative properties.

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