CHAPTER 1

INTRODUCTION

1.1 Research Background

A composite material is a macroscopic blending of two or more distinctive

materials which having a conspicuous interface between them. In addition, the mechanisms
and formation of interface and interphase between fibers and resins are needed in the
manufacture should have superior performance composite material. According to Shirazi
(2012), by consolidating essential material, composites can be intended to provide
structural properties and also as additional fundamental materials that have exceptional
properties for electrical, thermal, tribological, environmental, and biomedical application.

Moreover, Karapappas et al. (2011) indicated gelcoat is a material used to provide a

high-quality finish on the visible surface of a fiber-reinforced composite material. The
most widely recognized gelcoat is focused on epoxy or unsaturated polyester resin with
thoughtfulness regarding to Scholz et al. (2014), Keegan et al. (2013), Yardimcia et al.
(2013). Gelcoat is a modified resin which applied on mould in the liquid state.

Many current researchers like Gombos and Summerscales (2014), Landowski et al.
(2014), Salit (2014) and Raghavendra et al. (2013) are more to use different gel-coating
process or preparation method to fabricate low defect gelcoat in the mould. The main focus
is on the performance of gelcoat on their outlined product especially particularly with
respect to service period against harsh environment. The best author’s knowledge stated
that there still no experimental research done about the effect of gelcoat thickness on
laminate structure and strength. Thus, this is a very exceptionally topic to be explored in
detail to gain deep understanding on roles of different gelcoat thickness affect laminated
structure and strength.
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1.2 Problem Statement

One of the improvement required for composite properties is by enhancing in

gelcoat performance. For example, to get ideal fire retardancy out of laminate, it is
imperative that post curing at elevated temperature takes place. The process of post curing
diminishes the amount of residual styrene in a laminate. This has shown that previous
studies, for example like Sanjay et al. (2014) and Nguyen et al. (2013) have started alter
the substance of gelcoat to reach desired properties.

Sockalingam and Nilakantan (2012) specified chemical reaction occurred in

between the first layer of the laminate which is applied to gelcoat that has not completely
cured. The two layers were eventually cured together by a chemical bond in between them.
In the presence of interface, it should be noted that the fiber sizing region sometimes is
referred to the interface while the sizing matrix region is referred to interphase in view of
the chemical reactions occurred between the sizing and the resin during consolidation and
curing. It is undeniable that brittle gelcoat layer is due to excess of catalyst that cracks with
little provocation, while under cure is resulting from excessively little catalyst that produce
a flexible gelcoat (Lacovara, 2010). However, more flexible gelcoat is not inclined to
cracking, it is slanted toward premature color degradation, loss of gloss, chalking or
chemical attack. This is as explored by Mouritz and Gibson (2007) that the filler particles
blended into the liquid resin and consistently scattered to guarantee consistent flame
retardant properties throughout the polymer. Most polymers require a high stacking of
filler to show an appreciable improvement to their flammability resistance. The fillers have
different deleterious effects on the properties, including an increase to the viscosity and
reduction of gel time for the polymer melt which makes processing more difficult.

Based on the research above, the previous studies have generally concentrate on the
performance of gelcoat as the protective layer for laminate composite while by adjusting
the mixing ratio of catalyst and resin to control the curing of gelcoat. However, there are
only few studies are mentioned on the gelcoat thickness used, but not specified on it for
optimal purpose. Thus, this research is focusing on gelcoat thickness in order to optimize
the performance of laminated composite.

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1.3 Objectives

The objectives are as follows:

(a) To study the effect of gelcoat and thickness on the laminate composite
strength.

(b) To investigate the interface between the gelcoat and laminated composite
after mechanical testing.

(c) To propose the optimum thickness of gelcoat on laminated composite.

1.4 Scopes of the Research

The scopes of research are as follows:

(a) Research on the effects of gelcoat thickness on laminated composite based

on the mechanical and physical properties or and related issues. In this
research more focus on utilizing distinctive thickness of gelcoat which
resulting in term of strength.

(b) Study the potential of using spray up or hand lay-up method on gelcoat
application for the purpose of better thickness control, reduce material waste
that also can clean the equipment easily. Curing of remaining gelcoat at
nozzle is hard to be clean.

(c) Design the different thickness of gelcoat layer on the four plies and 0/90
degree orientation. From testing, result can clearly state the differences in
strength and also including the interphase interface between gelcoats and
laminated composite.

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 (d) Identify the appropriate amount of catalyst added into the gelcoat to control
the curing behaviour in considering the performance of gelcoat,
environment effect to human and surrounding which gelcoat contain
hazardous styrene.

1.5 Rational of Research

The rational of research as follows:

(a) Composite product might achieve their highest strength when the bonds
between layers of fiberglass are mechanical or primary bonds as opposed
stress transferring in between two layers before facing failure. This research
is developed to study the mechanical bond in between gelcoat and laminated
composite.

(b) Generate scientific information and deep understanding on the role of

catalyst in the curing behavior and performance of gelcoat. Gather the
useful information on technical data of gelcoat performance after run the
experiment approach.

(c) To gain new knowledge behind the experimental research by improve the
laminated composite quality and bring the engineering field to higher level
especially boat manufacture industry. Develop a new idea by control the
gelcoat thickness to enhance composite product with using standard amount
of catalyst to design a better product.

(d) Reduce the dependency to use less corrosive catalyst material that suitable
to environment and enhance the performance of gelcoat on laminated
composite strength such as polyether ether ketone, acetyl- acetone peroxide,
vinyl polymerization peroxide, benzoyl peroxide that are commonly used in
the gelcoat.

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1.6 Research Methodology

The entire research embodies five main parts which are Part 1 is material selection,
Part 2 is application of gelcoat on laminated composite, Part 3 is different gelcoat thickness
control on specimens, Part 4 is tensile test and two way of three point flexural bending test,
then data interpretation, analysis and correlations and lastly Part 5, conclusion and setting
up the research report. The summary of the research methodology as depicted in Figure
1.1.

Raw Material
Selection

Gelcoat Composite

Gelcoat Thickness

Gelcoat Application
(Spray-up and hand lay-up)

Specimen Testing
(Tensile, Two way of three point flexural test)

Data Analysis &

Result

Conclusion

Figure 1.1: Flow chart of framework

Firstly, Part 1 is selecting the suitable material for every parts that has the required
properties to provide the important execution in service which is also intimately connected
with the processing of the material into the complete parts. A deficient chosen material can
change the properties of the material and may influence the performance of the part.
Besides, Part 2 is utilizing the most suitable gelcoat application methods which are brush
and spray up application. This requires cautious consideration on gelcoat spreading and
curing behavior because uneven spreading may cause unstable testing result. Moreover,

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Part 3 is measurement of gelcoat thickness by using the wet film measurement gauge to
verify the gelcoat thickness cover equitably on laminated composite. Part 4 universal
testing machine and two way of three point flexural testing will be conducted to test the
mechanical bond and interface between the gelcoat and laminated composite. Furthermore,
Part 5 is focusing the data obtained during the test will be precisely interpreted, analyzed
and correlated. Part 6 is conclusion will be made by analyze all the analysis done in
previous part such as gelcoat thickness to produce the optimal product performance.

1.7 Thesis Organization

The organization of this thesis is as following. Chapter 1 is begin with research

background, problem statement, objectives, and scope of the research, rational of research
are delineated in order to better define particular aspects of gelcoat thickness on laminated
composite structure and strength performance addressed in this thesis. Chapters 2 literature
review comprises previous study or research about the gelcoat thickness, performance of
gelcoat, testing method, theory of interface and interphase. Chapter 3 methodology
describes all the raw materials, the hand lay-up and spray up method used to prepare the
gelcoat on the laminated composites, wet film measuring gauge to measure the thickness of
gelcoat is equitably spread on the surface, testing method used will be stated in the
research. Chapter 4 is analyze the information collected after running testing through
universal testing machine and two way three point flexural tests then discuss the effect of
gelcoat on laminate structure and strength. In Chapter 5, conclusion and recommendation
about this research are examined.

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 CHAPTER 2
LITERATURE REVIEW

This chapter is mainly describe the theory and research which have been defined
and done by various researcher years ago. Related information of previous studies are
extracted as references and discussion based on their research about gel coat thickness,
laminate composite structure, mechanical and physical properties.

2.1 Gelcoat

Borsting et al. (2010) describes gelcoat as a material used to provide a high quality
finish on the visible surface of the finished part of a fiber-reinforced composite material.
Gelcoats are applied to moulds in the liquid state. They are cured to form cross-linked
polymers and are subsequently backed up with composite polymer matrices, fiberglass or
epoxy resin with glass fibers and mixtures of polyester resin. Fiber Glass-Evercoat Corp
(2000) provide gelcoats typically consist of four classes of ingredients polymer, additives,
filler, and reactive diluents. It is important to achieve the proper thickness in the mostly
stressed areas because thickness is a critical control point for crack prevention or other
defects is mentioned by Lacovara (2010).

Gel coats must resist mechanical and thermal stresses encountered during the
curing and de-moulding process. Gel coat is designed to protect the exterior part of
composite product and is painted after the product is removed from the mould as reported
by Saltz (2009). Besides, Wright (2004) showed that polyester gel coat is first sprayed onto
the mould surface when built a polyester boat. The first layer of the laminate is applied to
gel coat is not fully cured. The two layers theoretically cure together by chemical bond
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between them. Based on the information obtained from Fiber Glass-Evercoat (2000), there
are three main categories of gelcoat. Table 2.1 show coverage, cure times, application of
gelcoat mentioned:

(a) Premium laminating gel coat.

A premium quality laminating polyester gel coat that remains tacky between
layers for easy re-coating. This air-inhibited product requires the use of a
mould release agent to seal off the air and ensure cure to a hard surface
when used as a final coat.

(b) One step finish gel coat.

A premium quality finish polyester gel coat that cures to a hard surface.
This gelcoat does not require the use of a mould release, but needs to be
sanded between the layers to ensure proper adhesion.

(c) Polyester gel paste.

A premium quality finishes polyester gel paste that cures to a hard surface.
This material used to fill deep gouges or fill in the spots where the gel coat
is damaged. This formula of thicker that the gel coat, and is ideal for
applications where material build is necessary.

Table 2.1: Coverage, cure times, application suggestions (Fiber Glass-Evercoat, 2000).
Working Time /
Fully
Product Name Coverage per gallon @ 0.25mm Apply Second
Cured (hours)
Coat (mins)
60 sq. feet per 1 gallon at 0.5mm
Premium gel coat 17 to 30 4 to 6
thickness (equals 20 sheets of paper)
One step finish gel 50 sq. feet per 1 gallon at 0.5mm
15 to 30 4 to 6
coat thickness (equals 20 sheets of paper)

2.2 Gelcoat Thickness

Lacovara (2010) proposed that method of application and conditions of entire

process are the major influence on the integrity of gel coat film. Gel coat film thickness is
the most important control point in the process. For most gel coats, the range of specified

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wet applied thickness is between 0.4 mm to 0.6 mm. This range may vary slightly with
specially formulated products. However, there is a specific optimum thickness range for
each formulation of gel coat required by the manufacturer of the product. Variations in gel
coat thickness can cause several problems ranging from under cure due to thin gel coat and
cracking cause by thick gel coat. Another critical view to consider is the average thickness
of gel coat on a part may not prevent cracking. For example, if a part averages 0.45 mm
thick, but the corner areas are 0.66 mm, localized cracking may occur over thick areas. It is
important to achieve the proper thickness in the most highly stressed areas of a part
because thickness is a critical control point for crack prevention, so the spray process are
temporary rated as the best method for gel coat application.

2.3 Gelcoating Process

Derek et al. (2013) explain gelcoating process is apply the epoxy or polyester type
gelcoat material to provide a high-quality finish on the visible surface of a fiber-reinforced
composite material. When it is sufficiently cured, it will be removed from the mould and
gelcoated surface are presented. It is usually pigmented to provide a glossy and coloured
surface to improve the aesthetic appearance of the product.

2.3.1 Brush and roller application

BUFA Gelcoat Plus Corporation (2008) analyzed that using brush is the easiest
method to apply gel coats. Brush method have the advantage in very good air release and
low emission of styrene. The gelcoat‘s pigmentation should be adjusted to make brush
strokes not visible. Ideally, each two layers of 300 μm are applied. The second layer is
applied after the first has initially cured and does not open when the second is brushed on.
However, it is not easy to maintain an even layer thickness over the whole piece with this
application method. A special hand application rolling method is mainly used for the
production of large moulded articles with large surfaces to achieve a relatively short
coating time. However, not every gelcoat in brush consistency is suitable for rolling and

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special formulations must often be selected for large surface objects. Figure 2.1 show the
brush and roller application.

Figure 2.1: Brush and roller Application (Dong, 2009).

2.3.2 Spray application

Saltz (2009) proved that spray application is better than brushing. Gel coats that are
optimized in regard to viscosity and air release are available for spraying. A lot of air
brought into the gel coat by spraying have caused emission of styrene is increased at the
same time. Spray technologies separate resin and gel coat liquids into a fine mist by
forcing the liquid under high pressure through an elliptical orifice, by bombarding a liquid
stream. The net result is some overspray that reduces the transfer efficiency of the material
sprayed onto moulds. The gun should be led perpendicular to the surface of the mould,
spraying length-wise and cross-wise at a distance of approximate 0.5 m, depending on the
material used and size of the spray nozzle. BUFA Gelcoat Plus Corporation (2008)
indicated to minimize the emission of styrene and optimize air release, the droplets formed
when spraying should be as large as possible and spraying pressure should very low. The
easiest spraying method is by using cup guns. Peroxide is added to a maximum of 2.5 kg of
gelcoat in the cup and sprayed onto the mould with compressed air. Cup guns are used for
smaller moulded articles when colours are changed often as shown at Figure 2.2.

Figure 2.2: Cup gun spray gun (Sommer et al., 2012).

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 CHAPTER 3
METHODOLOGY

This chapter describes the proposed methodology of this research which consist the
principles of methods that will be performed to complete the research. The selection of
material, designing, processing and testing will be presented as well after refer attentively
to the specification and particular of previous research. The main principle of methodology
is suggesting the suitable methods, recommended tool and techniques to complete this
research.

3.1 Overview

The preparation of methodology is to make sure the gel-coating and lamination

process are as planning and expected. The procedures set up is according to scopes of the
research in order to reach the objective set up. In addition, the ASTM is used as the
benchmark of all procedures involving standard tools, techniques and specimen testing.
Besides, the settings of procedures are also based on previous research. The flow chart
show at Figure 3.1 will describe overall process in obtain the final result which have
including the starting from material preparation, gel-coating process, testing method and
data analysis.

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 CHAPTER 4
RESULTS AND DISCUSSIONS

This chapter is mainly explain the data collected after complete the sample
fabrication and testing experiment. All the hypothesis and discussions will be stated that
supported by the previous research statement base on the effect of gelcoat thickness,
interface bonding, mechanical and physical properties.

4.1 Overview

The primary purpose in this research is different thickness of gelcoat which made
on 4-plies of glass fibers as reinforcement and polyester resin as matrix. The gelcoat
preparation is using hand lay-up technique to brush on the flat surface of the mold. While
the resin will spread on the glass fiber at other table before laminate on the gelcoat in term
to prevent affect the gelcoat thickness which still in the semi-liquid state when inconsistent
external force applied. There are total six different thickness which were 0.25 mm, 0.30
mm, 0.35 mm, 0.40 mm, 0.45 mm, 0.50 mm as tabulated in the Table 4.1. Tensile and
flexural test were used to analyze the mechanical properties of different gelcoat thickness
on 4-plies laminates. The interface bonding between the gelcoat and laminates were the
main point in this research in term to define the mechanical properties of the laminates.
The crack pattern or failure behavior will be differentiated due to the different gelcoat
thickness will cause different failure occur. It is needed to differentiate the suitable gelcoat
thickness for the laminate composite structure to reach desired properties. Figure 4.1 show
the sketching of gelcoated laminate composite that used in this research.

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 CHAPTER 5
CONCLUSIONS AND RECOMMENDATIONS

5.1 Conclusions

The first objective of this research is to study the effect of different gelcoat
thickness on the laminate composite strength via using tensile test and two-way three point
flexural test. The data collected are analysed and significant conclusions for this objective
as follows;

(a) Two way flexural test had determine that neither top nor bottom position,
the 0.30 mm was the best gelcoat thickness in sustaining the compression
load applied.

(b) Tensile test in purpose to study the interfacial bonding in between the
gelcoat layer and laminate composite had shown that 0.40 mm gelcoat
thickness is the highest pulling force from vertical direction.

The second objectives of this research are to investigate the interface between
gelcoat and laminate composite after mechanical testing. The load transferring in between
the gelcoat layer and laminate composite are the main factor in where the load applied.
These also the reason to conduct the two-way three point flexural test and tensile test to
determine the mechanical strength. The significant conclusion for this objective as follows;

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 (a) The most obvious failure is the brittle fracture of the gelcoat layer. Higher
the gelcoat thickness, the brittleness of gelcoat increase per each 0.05 mm.
There are clear and clean crack edge can be seen where the failure occur.

(b) The delamination of matrix occurs within the four plies. From the
observation on SEM, the interface of gelcoat and laminate composite are
strongly bonded in each gelcoat thickness and mostly final failure are cause
by the delamination.

(c) The only poor interface bonding was cause by the void appear at the
interface zone. The crack propagation had propagate through the void which
will lower the mechanical strength. It able to explain the inconsistent result
collected in eight same gelcoat thickness samples testing.

The third objectives of this research are to propose the optimum thickness of
gelcoat on laminate composite. Suitable gelcoat thickness is decided by according to
highest mechanical strength sustained after undergo the tensile and two-way three point
flexural test. The significant conclusions for this objective as follows;

(a) From the two-way three point flexural test, both test had shown that 0.30
mm are the highest stress sustained. By compare to pure laminate composite
which is no gelcoat layer, it is very obvious to show that gelcoat layer had
increase the mechanical strength of the composite.

(b) The tensile test had shown that 0.40 mm are the highest force sustained in
among other gelcoat thickness. The result obtained also shown that the force
sustained by each gelcoat thickness are increase normally which were no
much variation of each value.

(c) Thus the best gelcoat thickness range to apply on the laminate is 0.3 mm and
0.4 mm to perform the best performance.

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5.2 Recommendations

After gone through this research, there are few recommendations suggested so be
able to call attention to the important aspect need to be focus on for coming research topic
about gelcoat in the future. The significant recommendations for this objective as follows;

(a) The impact test is suggested for coming research topic on gelcoat to verify
the mechanical properties of gelcoat in facing the impact force like boat’s
body will bump with rock when reach the shore that crush on the hard
surface of the ground.

(b) The interfacial bonding strength or adhesion strength can be determined

more accurate through the Z-direction test which able to clarify the
interfacial bonding of gelcoat and laminate composite by reverse force
applied at both layer.

(c) High possibility to consider the chemical reaction occur in interfacial layer
that forming the chemical bond. There are still many other type gelcoat
material to be tested to discover the properties instead of single material.

5.3 Sustainability Element

This research was motivated by the innovation of incorporating aluminium mesh

into polymer matrix composite. The data and results obtained may contribute to the society
in many ways, especially in the engineering field. Engineering fields are wide and often
seek for improvement from time to time for the purpose of moving forward to the future.
At the same time, the societies that are related to engineering field certainly looking at the

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potential research that benefits themselves and others. This research will contribute to the
society as follows:

(a) First of all, a strong hybrid laminated composite that has impressive
mechanical and physical properties yet with lower density and weight which
can be used to replace the usage of metals. In addition, polymer matrix
composites are corrosion resistance that has longer service life. Hence, less
mining activities will be carried out. This is because mining causes
environmental issues such as erosion, loss of biodiversity as well as
contamination of soil, groundwater and surface water by chemical from
mining processes.

(b) Although the innovation is in the engineering material field, it can be

applied in the civil engineering field. Adaptation in term of design can be
made to suit the usage of material. Therefore, it is important to grasp the
understanding on how it behaves when the different matrix and
reinforcement materials are used together. The hybrid laminated composite
that contained aluminium mesh can be used to replace the steel mesh used
in the pillar. Steels are susceptible to corrosion when exposed to moisture
and mechanically affected. Concrete pillar made up of cement is porous
whereby diffusion of water via porous medium to reach the steel and
corrode the steel. The fabricated hybrid laminated composite has good
mechanical strength and moderately good water resistance properties such
as water absorption and thickness swelling.

5.4 Life Long Learning Element

5.5 Complexity Element

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