Current Trends and Industrial

Applications of Polymer
Composites

Dr.P.S.SAMPATH
Department of Mechanical Engineering
K.S.Rangasamy College of Technology
Tiruchengode-637215.
sampathps@rediffmail.com
 Contents
• Introduction
• Matrix Materials
• Reinforcement
• Manufacturing Techniques
• Industrial Applications
 What is a composite?

Composite, as its name suggests is a

combination of two or more dissimilar
materials.

The resultant composite will have

properties which are superior to
those of the individual components
 Are composites new materials?

No! Not at all.

The first composite was probably made

during Biblical time when man added
chopped straw to clay to make stronger
bricks.

The iron-rod reinforced concrete, widely

used in modern buildings, is also an
example of composites.
 But what is new?

Polymer composites are

comparatively newer materials.
As the usage of polymers is
increasing day by day in all
walks of life, research is being
carried out to improve their
properties to identify newer
applications.
What are the components present
in a Composite?
• A composite consists of a
continuous phase which is known as
a MATRIX in which a second
component is Reinforced.
The second component is known as
REINFORCEMENT.
• There are many matrix and
reinforcement materials which are
What are composite materials made
from?

Composite materials can also be put into

three main groups depending on their
matrix:
Polymer matrix composites (PMCs)
Metal matrix composites (MMCs)
Ceramic matrix composites (CMCs)
 Now let us discuss about the
selection of
the components of the composites:

Matrix materials:
Thermosets: Polyesters, Epoxies, Phenolics,
Silicones and Urethanes.
General Purpose Polyesters–Cheaper materials.
Epoxy – Ease of making the composites.
Phenolics – High Temperature Resistance, Low
smoke evolution- preferred for metro train panels.
Silicones – Heat resistant- used in solar panels.
Thermoplastics: PVC; Polypropylene;
Polyethyleneterephathalate (PET);
Polyamides (nylons), Polyimide, Polyacrylates.

Reinforcements:
• Glass fibres, Carbon fibers, Kevlar fibres, Polyester
fibres, Nylon fibres, Acrylic fibres, natural fibres.
• Glass fibres: E-; C; S; Z; M and D- Glass fibres
E-Glass: Corrosion and Environmental resistance.
C-Glass: Higher Acid Resistance.
Z-Glass: Corrosion and Alkali resistant.
 PRINCIPAL FIBRES

Aramid fibres
e.g. Kevlar, Twaron
Carbon Fibres
Glass Fibres
Natural fibres
flax, hemp, jute, kenaf, sisal
Polyethylene fibres e.g. Dyneema,
Spectra
Surface treatments on fibres
 Typical benefits include:
• High strength , Light Weight
• Corrosion Resistance
• Excellent Chemical & Electrical Resistance
• Dimensional Stability, Low tooling cost
• Design Flexibility
• Excellent fatigue resistance
• Reduced maintenance and long life spans
METHODS OF PRODUCTION
• Hand lay-up Process
• Pultrusion
• Compression Moulding
• Resin Transfer Moulding
• Resin Injection Moulding
• Vacuum Bag Moulding
• Spray-up Technique
• Filament Winding
What products are made by the fibre
reinforced composites?
• Many products!
• A. Aircraft Industry:
Advanced Light Helicopters,
B1-Bombers; Light canard Research
Aircraft; Many Aircraft parts.
Fig. Wing Torque Box
It took only a few years for composite materials to prove
themselves suitable for use in commercial aircraft.
Commercial aircraft are currently under design and manufacture (e.g., Airbus
380 and Boeing 7E7) that will make extensive use of composite materials.
Up to 60% of the structure of the 7E7 will be composite materials.
Unmanned combat air
vehicle (UCAV)
Northrop Grumman’s X-47A
unmanned combat air vehicle
(UCAV) is composed mainly of
carbon fibre/epoxy matrix
composites with a room
temperature cure (i.e., no need for
autoclave).
Wingspan of 8.5 m, length of 8.5 m,
and empty weight of 1,743 kg.
Tailless, kite-shaped vehicle allows
improved low-speed handling.
Unmanned combat air vehicle (UCAV)

Boeing X-45 military unmanned

combat air vehicle (UCAV) with a
planned combat radius of
approximately 2,000 km.

Fuselage consists of composite

skins (carbon fibre/epoxy matrix)
in addition to composite foam wings.
Upper skin is one piece of size 9 m x
3.7 m.

Higher temperature composite

(carbon fibre/bismaleimide) used
close to exhaust nozzle with
maximum service temperature of
204 ° C.
Aircraft fuselage

Portions of the fuselage for

the A380 will be produced
from glass-reinforced
aluminium laminate (known
as GLARE).
The resulting GLARE is
stronger than typical
aerospace materials (e.g.,
7075 aluminium) and a
fatigue life of 10~15 times
higher.
Civilian aircraft

The Airbus A380 currently

under manufacture will
make use of significant
amounts of composite
materials for the
fuselage, tail wing,
ailerons, and pressure
bulkhead.
Aerospace: Apollo spacecraft;
Saturn SII booster Launch
Vehicle, Rocket
bodies.
Saturn S-11 Space-craft
Space Shuttle Orbitor
Pioneer 10 Space craft
 Composites for Offshore
Applications
• Composite Piping System
• Composite Topside Applications
• Composite Grids/Gradings
• Composite Ladder & Handrail Components
• Flexible Thermosetting Tube
• Composite Pressure Risers
• High Pressure Accumulator Bottles
Composite in Automotive
applications
High performance cars

The use of carbon fibre/polymer

composites can result in weight
savings of 75~80% compared to
steel, 30~40% compared to
aluminium, and 50% compared
to chopped fibre glass
reinforced composite.

At least twenty five street legal

cars currently use carbon fibre
composites.
High performance cars

Ford produced a car

almost entirely from
carbon fibre composite as
long ago as 1979
in response to the high
fuel cost at that time.
Use of composite
materials reduced the
weight by 544 kg
compared to the
equivalent
steel version.
Trailer unit

The Composite trailer is

produced almost entirely from
Fibre glass/vinyl ester composite
including the floor, sides, roof,
cargo doors, and chassis.
The unit weighs 25% less
compared to an equivalent
metal trailer and has superior
corrosion resistance.
This combination is expected to
result in significantly reduced
operating costs.
Fibreglass tanks and tubes
The direct cost of metallic corrosion
in the U.S. is estimated to be US$
276 billion each year.
This is equivalent to 3% of gross
domestic product (GDP).

Examples include highways,

bridges, pipelines, water and
sewage systems, ships and aircraft,
industrial plants, and military
installations.
Fibreglass tanks and tubes

Fibreglass-reinforced vinyl
ester composite tanks with a
8.5 m diameter and 13 m
length was selected for use in
a waster treatment plant due
its excellent corrosion
resistance.
Similar composite tubes have
been used as a 142 m high
chimney stack liner.
Cryogenic Fuel Tank
Reusable one-piece liquid
hydrogen fuel tanks for launch
vehicles (up to 8.5 m diameter and
24.4 m long).
Composite fuel tanks are 10~25%
lighter compared to aluminum
tanks, allowing larger payloads
and/or reduced launch costs.
Important to design composite
tank to minimize permeation of the
tank by hydrogen molecules.
Power poles and cross
arms
Composite power poles and cross
arms to be marketed by largest
North American maker of wooden
utility poles.
Poles are produced from pultruded
fibre glass-reinforced polymer
composites.
Service life of >80 years makes them
ideal for installation in remote areas.
Non-conductive, lightweight cross
arms produced from pultruded fibre
glass-reinforced polyester.
Pultrusion Process
Wind turbine blades

The use of composite materials

in wind turbine blades has
resulted in large advances in
blade size and resulting power
output.
Wind turbine blades tend to
use mainly glass fibre
composites with highly
stressed regions being
reinforced with carbon fibre
composites.
Wind turbine blades

The largest wind turbine blade

currently has a length of 61.5 m
and weight of 18,000 kg.
The blade will be used on a 5
MW turbine with a diameter of
125 m.
The use of composite materials
for the blade decreases the
demands on the hub
components and tower
structure, decreasing capital
and operating expenses.
Wind turbine blades

Dynamic testing is used to

simulate the 20 year lifespan
of the blade (5 million
cycles).
The most important point for
wind turbine blades is to
reduce gravity-induced
bending loads, hence the use
of lightweight composite
materials.
Typical wind turbine blade
lengths are now up to 40 m.
Blade Type Rated Power

LM 29.1 P 1250 kW
LM 37.3P2 1500 kW
LM 34.0P3 2000 kW
LM 40.0 P 2000 kW
LM 40.3 P 1500 kW
LM 45.3P 2000 kW
LM 38.8 P 2500 kW
LM 43.8 P 2300 kW
LM 48.8 P 3000 kW
LM 61.5 P 5000 kW
Construction
In particular carbon fibre reinforced
composites offer exceptional stiffness and
strength properties compared to common metals

TWICE the stiffness of aluminium

-FIVE times stronger than aluminium
-FIVE times lighter than steel
Medical applications

Artificial limbs – composite

prosthesis.
Composite Prosthesis
 Sports

Sports bike, Motor bike, Power

boat, sail boat, rifles etc.
Fig. A Flax reinforced
Catamaran Hull
Composite sports Bicycle
Carbon fiber reinforced epoxy
bicycle frame
 Music

Musical instruments – Guitar –

Clear
and resonant sound
Composite Stringed Instruments
 Domestic Purpose:

Furniture, roofing etc.

The applications of composites
is ever increasing.
Furniture made up of
Composite
Resin Transfer Moulding
 RTM Applications
• Auto body panels • RV components
• Truck air deflectors • Propellers
• Wind blades • Bathtub/shower
• Chemical storage units
tanks • Antenna dishes
• Solar collectors • Chairs
(40 ft diameter, • Swim pool pane
36 parts)
Resin Infused Part
NATURAL FIBER
COMPOSITES
 Natural fibers
• Bamboo, Sisal
• Coir ,Banana
• Pineapple Leaf Fibre
• Jute, Tamarind Fruit
• Ridge Gourd Vegetable
Fabric
• Borassus Fruit Fibres
• Napier Grass
• Flax
 Borassus Fruit Fibres

Coarse Fibres Fine Fibres

 Advantages

• Renewable
• Low Cost
• Eco Friendly
• Cellular Structure (Micro pores)
 Disadvantages of natural fiber
composites
• Lower Aspect ratio
• Lower thermal stability
• Non-Uniformity in dimensions
NANO COMPOSITES
Nanomaterials and Some Current Products
• Fullerenes and Carbon Nanotubes: Fabrics,
Cosmetics,
Electronics, Sports Equipment, Lubricants, Building
Materials, Food Supplements, Food Flavorings
• Silver: Antibacterials, Antifungals, Self-Cleaning Glass,
Spermicidal Condoms, Food Storage Containers, Air
Sanitizer
• Silica: Electronics, Paints/Pigments, Cosmetics, Food
Supplements
• Zinc Oxide and Titanium Oxide: Clear – thin film
sunscreens, Cosmetics, Self-Cleaning Coatings, Lens
Defoggers
• Gold: Chemical Detection, Home Pregnancy Tests,
Nano Composite Applications