Assignment : Composite Materials

1) Specify the requirements and precautions relating to the storage and use of thermosetting
polyester resins, accelerators and catalysts
Thermosetting polyester resin
The proper storage of thermoset materials is key to maintaining their processability. Many
thermoset materials have a limited theoretical shelf life as determined by standardized laboratory
measurements. While shelf life is affected by ambient temperature, it is equally dependent on the
latitude and parameters of the molding process coupled with the tool and part design. The changes
in flow characteristics that occur during the shelf life of the material do NOT occur suddenly. They
occur gradually over a period of time and therefore affect each application differently. Thermoset
materials should always be stored in their unopened original containers until ready for use. If the
original container is opened but all the material is not used, the container should be resealed to help
prevent the gain or loss of moisture or the loss of volatiles. If the container is a paper bag, then place
it inside a sealable plastic liner. Thermoset materials should always be stored in a clean, dry
environment to prevent their increasing in moisture content. Thermoset materials are stored at
temperatures below room temperature they should be allowed to warm to at least room
temperature before attempting to mold. The colder the temperature the material is stored at, the
longer it will take for all the material in the container reach room temperature. If the material is
stored at or below freezing, it can take several days for all of it to reach room temperature. Problems
with moldability or preformability can occur when attempting to use them at colder temperatures.
Thermoset materials should be stored in a sealed container until needed for molding. If possible, the
container should have a sealable plastic liner which will help prevent the preforms from gaining or
losing moisture.
Accelerators
Various accelerators and promoters, like cobalt compounds, tertiary amines etc, should be handled
carefully. Always consult the MSDS for safety information. Accelerators and promoters can react
violently with organic peroxides, so keep these products away from direct contact with organic
peroxides, and don’t store peroxides and accelerators in the same area. When preparing the resin,
always add the accelerators and promoters first and stir carefully. Add the peroxide as the last
component.
Catalysts
Catalysts or call as organic peroxides are heat sensitive and thus thermally unstable chemical
compounds that have to be stored and handled with great care. They will decompose significantly
above certain temperatures, which will vary from peroxide to peroxide. When storing organic
peroxides strict rules have to be followed. Most catalysts used for the curing of unsaturated
polyester resins can be safely stored at a maximum of room temperature: although some require
cooled storage and transportation. Always consult the technical datasheet for the product in
question. Organic peroxides are also sensitive to contamination. Dust from trimming, grinding and
any other production waste can start a decomposition reaction so always keep containers closed and
use clean vessels to decant peroxide. When removing a quantity of catalyst from its container, never
put the excess quantity back into the container. Organic peroxides should not be allowed to come
into contact with any strong oxidizing agents (accelerators and promoters), strong acids and bases,
and metals like copper, brass and even rust. For cleaning smaller spillages paper or rags can be used,
but they must be disposed of in fireproof containers. An inert absorbent material, such as
vermiculite, should be used for larger spillages. This should be soaked with water after clean-up, and
deposited in a fireproof waste container. If peroxide spills onto working cloths, remove them
immediately, and when handling peroxides, eye protection must always be worn. Peroxide splashes
into eyes are very harmful, so if this occurs, flush immediately with plenty of water and always seek
medical advice. Small amounts of residual organic peroxides can be used to gel and cure resin waste
in a controlled way. Larger amounts can be destroyed through controlled burning, but must be
treated according to local regulations and instructions. Peroxide waste must not be stored in closed
or air-tight containers. As general rule, empty peroxide containers should be treated as special
waste, and local authorities should be consulted in this respect.

2) Specify the requirements and precautions related to the storage and use of epoxy resins and
hardeners
When using and handling epoxy resins a Material Safety Data Sheet (MSDS) should be obtained and
reviewed. The MSDS contains instructions, precautions, recommendations, and possible hazard
potentials with the use of that material. Anyone who is expected to use, handle, or have exposure to
the material should review and understand the instructions and recommendations contained with
the MSDS. The base component in most common epoxy resins are a reaction product of
Epichlorohydrin and Bisphenol A or Bisphenol F. Epoxy Resin Formulations usually contain other
components such as reactive diluents, solvents, fillers, pigments, and other additives, which
contribute to the system’s physical properties. Hazards associated with epoxy resin formulations will
depend on the hazardous properties of its components and amounts associated within the
formulation. Epoxy resins can have hazardous properties but are generally safe to use when handled
properly. Most epoxy resins are considered and classified as “Irritants”. They are usually considered
as mild to moderate irritants to the eye, skin, and mucous membranes. Epoxy resins are dermal
sensitizers with increased irritant potential with prolonged exposure to the skin. Due to the “sticky”
nature of epoxy resins, Dermal Exposure is the most likely route of exposure. Individuals with dermal
sensitivity may have an increased susceptibility. Personal protective equipment such as gloves, eye
protection, protective clothing, and respirators should be considered before handling epoxy resins.
There are many types of personal equipment, which offer various safety benefits. The determination
of the correct protective equipment is dependent on the hazards present during the application.
Once the hazards are identified, personal protective equipment should be selected which will
minimize exposure and allow maximum protection. Two component epoxy resin systems should be
stored in a control temperature. Refrigeration will not enhance the storage stability of two
component epoxy resin systems. Most two-component epoxy resin systems are naturally susceptible
to crystallization, especially at temperatures below the recommended storage temperatures.
Containers should be stored in clean dry areas with adequate ventilation. Do not store near sources
of heat. All lids should be securely fastened to prevent foreign matter contamination and moisture
entry.
3) State the reasons for the permitted wide range of polyester resin/catalyst ratios and the tightly
controlled resin/hardener ratios for epoxy systems.
Polyester is a highly reactive resin system and once the resin has been mixed with the catalyst, the
reaction will start to give off heat (exotherm) which will further accelerate the cure of the resin,
especially when the resin is in the mixing pot. Transfer the resin from the mixing pot onto the part as
soon as possible to extend the working time and avoid the risk of uncontrollable rapid cure in the
mixing pot. As with all Polyester resins, the pot-life/working time will vary significantly depending on
the ambient temperature, the starting temperature of the resin, catalyst ratio and the amount of
resin mixed. In resin rich: if too much resin is used, for nonstructural applications this is not
necessarily bad, but it adds weight. A part is called resin starved if too much resin is bled off during
the curing process or if not enough resin is applied during the wet layup process. Resin-starved areas
are indicated by fibers that show to the surface. The ratio of 60:40 fiber to resin ratio is considered
optimum. Sources of manufacturing defects include: Improper cure or processing, improper
machining, mishandling, improper drilling, tool drops, contamination, improper sanding,
substandard material, inadequate tooling, mislocation of holes or details damage can occur at
several scales within the composite material and structural configuration. This ranges from damage
in the matrix and fiber to broken elements and failure of bonded or bolted attachments. The extent
of damage controls repeated load life and residual strength and is critical. Manufacturing damage
includes anomalies, such as porosity, microcracking, and delaminations resulting from processing
discrepancies. It also includes such items as inadvertent to damage tolerance.
4) Specify the requirements and precautions for storage and use of fibres, fibre fabrics, sandwich
core materials and impregnated fibre fabrics.
Fibres, Fibre Fabrics
Many types of reinforcement fibers are currently available. The fibers that have been used include:
glass, aramid, carbon (graphite) and boron. Reinforcements like ceramic fibers, metallic fibers, and
whiskers have also been used in specific applications. There are few precaution being taking when
using carbon fibre. Prevention of generating plumage, dust and fly .Troubles brought about by
handling of Carbon Fibers are mainly caused by fuzz, dusts or fly generated during the handling of
the fibers. As Carbon Fiber staple products are more or less fly-like, local air exhaustion is effective
for avoiding any trouble during unpacking, taking out of packing or processing of the material. The
identical measures are advisable in cutting down long continuous yarn to produce chopped fiber or
in crushing the same to produce milled. Prevention of hazards to human body. Being presented that
Carbon Fiber yarn is "tough", peoples sometime try to tear off the yarn to make sure of that. Rather
often, fingers or palms, instead of the yarn, are damaged. Please be warned that it is a hazardous
challenge. Sticking to skins. Only by soft touching of dusts or fly to skins, one may feel pains or itch.
Never try to "rubbing off". As a string of Carbon Fiber is just like a metal fine wire or pin, the dust
penetrates into the skins more deeply causing the secondary inflammations. The best way is washing
out a local skin by cold or hot water; pouring running water on with a help of soap. Another effective
way is to make puffing by a strip of bundle tape or sticking tape. Itchy feeling on skins does usually
not stay for long time. The stuck fiber will leave off skins in half a day. Coating protective cream on
the skin is also recommendable particularly effective to be protected from high elastic modulus
Carbon Fibers. While during Handling and Storing of carbon, handling: wear protection gears of
skins, eyes and throats to prevent them from hazards of Carbon Fiber dusts or fly. Work out
preventive measures for short-circuits of electric lines caused by the dust or fly. Storing: Avoid
storing under the sunshine and in warm and wet environment. Though Carbon Fiber itself dose not
deteriorate, packing material, paper rolls and sizing agents degenerate. Some types of Carbon Fiber
may be gradually oxidized by atmospheric oxygen under temperature higher than 150 degree and so
generated heat piles up to possibly cause fire. Kindly refer to manufacturers' MSDS.
Sandwich core materials
Sandwich construction has found extensive application in aircraft, missile and spacecraft structures
due to high strength to weight ratio. This type of construction consists of thin, stiff and strong sheets
of metallic or fiber composite material separated by a thick layer of low density material. The thick
layer of low density material commonly known as core material may be light foam type or metallic
honeycomb corrugated core. The core material is generally adhesively bonded to the face sheets.
The core should not be exposed to extremes of temperature or humidity which cause moisture to be
absorbed. Ideal storage conditions are between 10° and 30ºC and below 70%RH and kept in the
original packaging until the time of use. The main function of a core material is to provide a light and
stiff sandwich panel, for which a good bond to the laminate skin is needed. To achieve this storing
the foam such that it is clean and dust free is critical. Direct exposure to sunlight should be avoided
as in the short term this will discolour the foam and the in the long term may degrade the surface
properties.
Impregnated fibre fabrics
Prepreg material consists of a combination of a matrix and fiber reinforcement. It is available in
unidirectional form (one direction of reinforcement) and fabric form (several directions of
reinforcement). All five of the major families of matrix resins can be used to impregnate various fiber
forms. The resin is then no longer in a low-viscosity stage, but has been advanced to a B stage level
of cure for better handling characteristics. The following products are available in prepreg form:
unidirectional tapes, woven fabrics, continuous strand rovings, and chopped mat. Prepreg materials
must be stored in a freezer at a temperature below 0 °F to retard the curing process. Prepreg
materials are cured with an elevated temperature. Many prepreg materials used in aerospace are
impregnated with an epoxy resin and they are cured at either 250 °F or 350 °F. Prepreg materials are
cured with an autoclave, oven, or heat blanket. They are typically purchased and stored on a roll in a
sealed plastic bag to avoid moisture contamination. For optimum performance and processability,
prepreg should be stored and sealed in plastic to prevent moisture absorption during storage as well
as when the product is brought out to stabilize to room temperature. Since condensation may form
during this stabilization period, the sealed plastic barrier prevents the condensation from being
absorbed by the prepreg. Do not remove the plastic from the prepreg until the material has
equilibrated to room temperature and no condensation is present. Prepreg should be stored at
room temperature (75°F) or lower. While recognizing that refrigerated storage is best to retain
product shelf life and out time, prepregs should be stored at less than 55% humidity at ambient
working conditions and used quickly when exposed to room temperature. Temperatures above 75°F
will appreciably shorten the useful working life of prepreg products.