Banana and abaca fiber-reinforced plastic composites obtained by rotational molding process

Natural fibers can be used in rotational molding process to obtain parts with improved mechanical properties. Different approaches have been followed in order to produce formulations containing banana or abaca fiber at 5% weight, in two- and three-layer constructions. Chemically treated abaca fiber has also been studied, causing some problems in processability. Fibers used have been characterized by Fourier transform infrared (FTIR) spectroscopy, thermogravimetric analysis (TGA), optical microscopy, and single-fiber mechanical tests. Rotomolded parts have been tested for tensile, flexural, and impact properties, demonstrating that important increases in elastic modulus are achieved with these fibers, although impact properties are reduced. © 2013 Copyright Taylor and Francis Group, LLC.

Advances in single-shot, dry drilling of composite/metal stacks

Carbon fibre reinforced polymers (CFRP) are increasingly being used in the aerospace, automotive and defence industry due to their high specific stiffness and good corrosion resistance. In a modern aircraft, 50-60% of its structure is made up of CFRP material while the remainder is mostly a combination of metallic alloys (typically aluminium or titanium alloys). Mechanical fastening (bolting or riveting) of CFRP and metallic components has thus created a pressing requirement of drilling several thousand holes per aircraft. Drilling of stacks in a single-shot not only saves time, but also ensures proper alignment when fasteners are inserted, achieving tighter geometric tolerances. However, this requirement poses formidable manufacturing challenges due to the fundamental differences in the material properties of CFRP and metals e.g. a drill bit entering into the stack encounters brittle and abrasive CFRP material as well as the plastic behaviour of the metallic alloy, making the drilling process highly non-linear.

Over the past few years substantial efforts have been made in this direction and majority of the research has tried to establish links between how the process parameters (feed, depth of cut, cutting speed), tooling (geometry, material and coating) and the wear of the cutting tool affect the hole quality. Similarly, multitudes of investigations have been conducted to determine the effects of non-traditional drilling methods (orbital, helical and vibration assisted drilling), cutting zone temperatures and efficiency of chip extraction on the hole quality and rate of tool wear during single shot drilling of CFRP/alloy stacks.

In a timely effort, this paper aims at reviewing the manufacturing challenges and barriers faced when drilling CFRP/alloy stacks and to summarise various factors influencing the drilling process while detailing the advances made in this fertile research area of single-shot drilling of stack materials. A survey of the key challenges associated with avoiding workpiece damage and the effect these challenges have on tool design and process optimisation is presented. An in depth critique of suitable hole making methods and their aptness for commercialisation follows. The paper concludes by summarising the future work required to achieve repeatable, high quality single shot drilled holes in CFRP/alloy stacks.

An energy based force prediction method for UD-CFRP orthogonal machining

The machining of carbon fiber reinforced polymer (CFRP) composite presents a significant challenge to the industry, and a better understanding of machining mechanism is the essential fundament to enhance the machining quality. In this study, a new energy based analytical method was developed to predict the cutting forces in orthogonal machining of unidirectional CFRP with fiber orientations ranging from 0° to 75°. The subsurface damage in cutting was also considered. Thus, the total specific energy for cutting has been estimated along with the energy consumed for forming new surfaces, friction, fracture in chip formation and subsurface debonding. Experiments were conducted to verify the validity of the proposed model.

Basalt Fibre Reinforced Polymer Strengthening of Normal Strength Reinforced Concrete Floor Slabs Subject to Arching Effects

With ever increasing demands to strengthen existing reinforced concrete structures to facilitate higher loading due to change of use and to extend service lifetime, the use of fibre reinforced polymers (FRPs) in structural retrofitting offers an opportunity to achieve these aims. To date, most research in this area has focussed on the use of glass fibre reinforced polymer (GFRP) and carbon fibre reinforced polymer (CFRP), with relatively little on the use of basalt fibre reinforced polymer (BFRP) as a suitable strengthening material. In addition, most previous research has been carried out using simply supported elements, which have not considered the beneficial influence of in-plane lateral restraint, as experienced within a framed building structure. Furthermore, by installing FRPs using the near surface mounted (NSM) technique, disturbance to the existing structure can be minimised.
This paper outlines BFRP NSM strengthening of one third scale laterally restrained floor slabs which reflect the inherent insitu compressive membrane action (CMA) in such slabs. The span-to-depth ratios of the test slabs were 20 and 15 and all were constructed with normal strength concrete (~40N/mm2) and 0.15% steel reinforcement. 0.10% BFRP was used in the retrofitted samples, which were compared with unretrofitted control samples. In addition, the bond strength of BFRP bars bonded into concrete was investigated over a range of bond lengths with two different adhesive thicknesses. This involved using an articulated beam arrangement in order to establish optimum bond characteristics for use in strengthening slab samples.

Glass fibre-reinforced polyethylene composites in rotational moulding

Fibre-reinforced mouldings are of growing interest to the rotational moulding industry due to their outstanding price performance ratio. However, a particular problem that arises when using reinforcements in this process is that the process is low shear and good mixing of resin and reinforcement is not optimum under those conditions. There is also a problem of the larger/heavier reinforcing agents segregating out of the powder to lay up on the inner part surface. In this paper we report on studies to incorporate, short glass fibres into rotationally moulded parts. Four different approaches were investigated; direct addition of fibre in between two powder shots, addition of a layer of pre-compounded polyethylene-glass fibre pellets between two powder shots, addition of a layer of pre-compounded polyethylene-glass fibre powder between two powder shots and a single layer of glass-reinforced, pre-compounded powder. Results indicate that pre-compounding is necessary to gain performance enhancement and the single layer part made from glass-reinforced, pre-compounded powder exhibited the highest tensile and flexural modulus.

Monitoring and model updating of an FRP pedestrian truss bridge

This paper presents the results of a real bridge field experiment, carried out on a fiber reinforced polymer (FRP) pedestrian truss bridge of which nodes are reinforced with stainless steel plates. The aim of this paper is to identify the dynamic parameters of this bridge by using both conventional techniques and a model updating algorithm. In the field experiment, the bridge was instrumented with accelerometers at a number of locations on the bridge deck, recording both vertical and transverse vibrations. It was excited via jump tests at particular locations along its span and the resulting acceleration signals are used to identify dynamic parameters, such as the bridge mode shape, natural frequency and damping constant. Pedestrianinduced vibrations are also measured and utilized to identify dynamic parameters of the bridge. For a complete analysis of the bridge, a numerical model of the FRP bridge is created whose properties are calibrated utilizing a model updating algorithm. Comparable frequencies and mode shapes to those from the experiment were obtained by the FE models considering the reinforcement by increasing elastic modulus at every node of the bridge by stainless steel plate. Moreover, considering boundary conditions at both ends as fixed in the model resulted in modal properties comparable/similar to those from the experiment. This study also demonstrated that the effect of reinforcement and boundary conditions must be properly considered in an FE model to analyze real behavior of the FRP bridge.

Direct spun aligned carbon nanotube web-reinforced proton exchange membranes for fuel cells

A new method combining electrospinning of SPEEK and direct spinning of CNT forests has been used to prepare sulfonated poly(ether ether ketone) (SPEEK)/directly spinnable carbon nanotube (dsCNT) composite proton exchange membranes. The SPEEK/dsCNT membrane is more robust than SPEEK alone, and in a fuel cell significantly outperforms both SPEEK and the commercial Nafion 212 membranes.