FABRICATION OF COMPOSITE

3.4 Basic Raw materials

1. Reinforcing material 2. Matrix material

3.4.1 REINFORCEMENTS
These are fibrous materials, when introduced into polymer matrix produce a dramatic improvement in physical properties of a composite. Reinforcement improves overall mechanical properties of the matrix. The reinforcing filler usually takes the form of fiber but particles (for e.g. Glass spheres) are also used. A wide range of amorphous and crystalline materials can be used as reinforcing fibers. These include glass, carbon, boron and silicon. In recent years, fibers have been produced from synthetic polymers for e.g. Kevlar fibers Glass in the form of fibers is relatively inexpensive and is the principal form of reinforcement used in plastics. Drawing of continuous stands of glass from an orifice in the base of an electrically heated platinum crucible, which contains molten glass, produces the fibers. The earliest successful glass reinforcement had a calcium-alumina borosilicate composition developed specifically for insulation purpose (E-glass). The use of reinforcement fibers can result in the following changes.

Increase in modulus of elasticity and stiffness Lower shrinkage Low temperature dependency of mechanical and physical properties Increase in tensile, compressive and flexural strength.

Unidirectional

Bi-directional

Discontinuous Fiber

Woven

Fig 3.3: Fiber reinforced composites

3.4.2GLASS FIBER:
Fiberglass or glass fiber is material made from extremely fine fibers of glass. It is used as a reinforcing agent for many polymer products, the resulting composite material, properly known as Fiber-Reinforced Polymer (FRP) or Glass-Reinforced plastic (GRP), is called fiberglass in popular usage. Fiberglass is shown in fig. 2.3.

Fig 3.4.1: Glass fiber

3.4.3 Hemp
Hemp fiber is one of the important lignocellulosic bast fiber and has been used as reinforcement for industrial applications. Hemp fiber is one of the inexpensive and readily available best natural fibers and hemp-fiber reinforced polymer composite products have gained considerable attraction for automotive interior products.

Fig 3.4.2:Hemp

3.5MATRIX
The matrix is the material that gives body and grips or holds the reinforcements of the composites together, and is usually of lower strength than the reinforcement. The matrix must be capable of being forced around the reinforcement during some state in manufacture of composite. Typically, composite material is formed by reinforcing fibers in matrix resin is shown in fig 2.2 Resign is organic polymer used as a matrix to contain fibrous reinforcement in composite material or as an adhesive.

Fig 3.2: Formation of composite material using fibers and resin

The purpose of matrix is to provide:

Load transfer to fibers Dimensional stability Fiber support Protection Good surface finish quality

3.5.1 Lapox L-12(Epoxy)

Lapox L-12 is a liquid, unmodified epoxy resin of medium viscosity which can be used with various hardeners for making reinforced composite and laminates. The choice of hardener depends upon the processing method to be used and on the properties required of the cured composite.

3.5.2 Hardener K-6

Hardener K-6 is a low viscosity room temperature curing aliphatic amine curing agent. It is commonly employed for civil engineering system where low viscosity and fast setting at ambient temperature is desired.

3.5.3 Typical Properties

Epoxy Resin( Lapox L-12) Appearance Epoxy Value Hydrolysable chlorine Viscosity at 250 Volatile content ------eq/kg % mPas % Clear pale yellow liquid 5.25-5.4 .1max 10,000-12,000 .55max

Hardener K-6
Appearance Viscosity at 250 Refractive Index

-------mPas

Clear pale yellow liquid

10-23 1.4940-1.5000 1max

Water content

3.4.6 FABRICATION BY HAND LAY-UP TECHNIQUE

In this process resins are impregnated by hand into fibers which are in the form of woven or bonded fabrics. Hand layup process usually accomplished by rollers or brushes. The composite plates from which the test specimens were fabricated by employing the traditional Hand layup technique. This is a very popular method of composite fabrication, limited by its ability to produce simple shapes. Initially, a plate consisting of epoxy resin with glass and hemp fiber re-inforcement was fabricated. The plate was made up of 55% fiber and 45% Resin by weight.

3.4.7 FABRICATION STEPS:

1) The bottom slab of the mould (granite slabs) is thoroughly cleaned with acetone and release film is spread on it. 2) Initially, a plate consisting of Vinyl Ester resin with glass fiber reinforcement is fabricated without the addition of particulate fillers. This plate consists of 55% glass fiber and 45% Vinyl Ester by weight. 3) Subsequent fabrication of plates involves addition of Boron Carbide in steps of 3%, 6% and 9% by weight of Vinyl Ester resin. 4) The initial material preparation includes getting the glass fabric cut to the desired size. Each plate consists fourteen such fabrics. 5) The weight of fourteen fabrics is determined, in accordance with which the quantity of resin to be used is decided in such a way that the final plate is made up of 45% resin and 55% reinforcement by weight 6) The resin is taken in two separate bowls (because of the relatively short gelling time of Vinyl Ester which was 20mins.), each bowl containing half the total weight. 7) The curing additives are added in the specified proportions, stirred thoroughly and the first resin coat is applied on the release film as per the size of the fabric. 8) The first layer of fabric is carefully placed over the resin coat in and thorough compaction is achieved to prevent air bubble entrapment. 9) This is followed by the application of alternate layers of resin and reinforcement and after laying seven fabrics, the resin from the second bowl (mixed with curing agents just before use) is used for the remaining seven layers and after the final resin coat is applied, the layup is covered by another release film. The mould is closed by placing the top slab. 10) The top slab on account of its weight (18 kg) compresses the lay-up to the desired thickness of 2.5mm, which is maintained using appropriate stoppers and the lay- up is allowed to cure for 6-8 hours before it is retrieved from the mould. 11) The above steps are repeated to fabricate seven plates, namely: without filler, with 3% Boron carbide filler, with 6% Boron carbide filler, with 9% Boron carbide filler.

Fig.5.1: Granite Slabs forming the mold.

Fig 5.2: Affixation of Release Film

Fig.5.3: Application of first resin coat.

Fig.5.4: Placement of Glass Fabric.

Fig.5.5: Placing release film over the lay-up Fig.5.6: Curing Stage