Drilling damage in composite material

The characteristics of carbon fibre reinforced laminates have widened their use from aerospace to domestic appliances, and new possibilities for their usage emerge almost daily. In many of the possible applications, the laminates need to be drilled for assembly purposes. It is known that a drilling process that reduces the drill thrust force can decrease the risk of delamination. In this work, damage assessment methods based on data extracted from radiographic images are compared and correlated with mechanical test results—bearing test and delamination onset test—and analytical models. The results demonstrate the importance of an adequate selection of drilling tools and machining parameters to extend the life cycle of these laminates as a consequence of enhanced reliability.

Finite Element Analysis (FEA) applied to heat transfer optimization process of pultrusion die systems

The aim of this study is to optimize the heat flow through the pultrusion die assembly system on the manufacturing process of a specific glass-fiber reinforced polymer (GFRP) pultrusion profile. The control of heat flow and its distribution through whole die assembly system is of vital importance in optimizing the actual GFRP pultrusion process. Through mathematical modeling of heating-die process, by means of Finite Element Analysis (FEA) program, an optimum heater selection, die position and temperature control was achieved. The thermal environment within the die was critically modeled relative not only to the applied heat sources, but also to the conductive and convective losses, as well as the thermal contribution arising from the exothermic reaction of resin matrix as it cures or polymerizes from the liquid to solid condition. Numerical simulation was validated with basis on thermographic measurements carried out on key points along the die during pultrusion process.

Mathematical modeling and simulation of heat flow through pultrusion die assembly system for thermoset composites

Pultrusion is an industrial process used to produce glass fibers reinforced polymers profiles. These materials are worldwide used when performing characteristics, such as great electrical and magnetic insulation, high strength to weight ratio, corrosion and weather resistance, long service life and minimal maintenance are required. In this study, we present the results of the modelling and simulation of heat flow through a pultrusion die by means of Finite Element Analysis (FEA). The numerical simulation was calibrated based on temperature profiles computed from thermographic measurements carried out during pultrusion manufacturing process. Obtained results have shown a maximum deviation of 7%, which is considered to be acceptable for this type of analysis, and is below to the 10% value, previously specified as maximum deviation. © 2011, Advanced Engineering Solutions.

Eco-efficiency approaches towards a sustainable composite materials manufacturing industry’

In this study the potential eco-efficiency performance of a pultrusion manufacturing company was assessed. Indicators values and eco-efficiency ratios were estimated taking into account the implementation of new proceedings and procedures in the production process of glass fibre reinforced polymers (GFRP) pultrusion profiles. Two different approaches were foreseen: 1)Adoption of a new heating system for pultrusion die in the manufacturing process, more effective and with minor heat losses; and 2) Recycling approach, with partial waste reuse of scrap material derived from manufacturing, cutting and assembly processes of GFRP profiles. These features lead to significant improvements on the sequent assessed eco-efficiency ratios of the present case study, yielding to a more sustainable product and manufacturing process of pultruded GFRP profiles.

Stress Ratio Effects on the fatigue Properties of Biaxially Loaded Tubular FRP-Specimens – Experimental Study

In this work tubular fiber reinforced specimens are tested for fatigue life. The specimens are biaxially loaded with tension and shear stresses, with a load angle β of 30° and 60° and a load ratio of R=0,1. There are many factors that affect fatigue life of a fiber reinforced material and the main goal of this work is to study the effects of load ratio R by obtaining S-N curves and compare them to the previous works (1). All the other parameters, such as specimen production, fatigue loading frequency and temperature, will be the same as for the previous tests. For every specimen, stiffness, temperature of the specimen during testing, crack counting and final fracture mode are obtained. Prior to testing, a study if the literature regarding the load ratio effects on composites fatigue life and with that review estimate the initial stresses to be applied in testing. In previous works (1) similar specimens have only been tested for a load ratio of R=-1 and therefore the behaviour of this tubular specimens for a different load ratio is unknown. All the data acquired will be analysed and compared to the previous works, emphasizing the differences found and discussing the possible explanations for those differences. The crack counting software, developed at the institute, has shown useful before, however different adjustments to the software parameters lead to different cracks numbers for the same picture, and therefore a better methodology will be discussed to improve the crack counting results. After the specimen’s failure, all the data will be collected and stored and fibre volume content for every specimen is also determinate. The number of tests required to make the S-N curves are obtained according to the existent standards. Additionally are also identified some improvements to the testing machine setup and to the procedures for future testing.

Estudo da delaminação em compósitos

As excelentes propriedades mecânicas, associadas ao seu baixo peso, fazem com que os materiais compósitos sejam atualmente dos mais interessantes da nossa sociedade tecnológica. A crescente utilização destes materiais e a excelência dos resultados daí provenientes faz com que estes materiais sejam utilizados em estruturas complexas de responsabilidade, pelo que a sua maquinagem se torna necessária de forma a possibilitar a ligação entre peças. O processo de furação é o mais frequente. O processo de maquinagem de compósitos terá como base os métodos convencionais utilizados nos materiais metálicos. O processo deverá, no entanto, ser convenientemente adaptado, quer a nível de parâmetros, quer a nível de ferramentas a utilizar. As características dos materiais compósitos são bastante particulares pelo que, quando são sujeitos a maquinagem poderão apresentar defeitos tais como delaminação, fissuras intralaminares, arrancamento de fibras ou dano por sobreaquecimento. Para a detecção destes danos, por vezes a inspeção visual não é suficiente, sendo necessário recorrer a processos específicos de análise de danos. Existem já, alguns estudos, cujo âmbito foi a obtenção de furos de qualidade em compósitos, com minimização do dano, não se podendo comparar ainda com a informação existente, no que se refere à maquinagem de materiais metálicos ou ligas metálicas. Desta forma, existe ainda um longo caminho a percorrer, de forma a que o grau de confiança na utilização destes materiais se aproxime aos materiais metálicos. Este trabalho experimental desenvolvido nesta tese assentou essencialmente na furação de placas laminadas e posterior análise dos danos provocados por esta operação. Foi dada especial atenção à medição da delaminação causada pela furação e à resistência mecânica do material após ser maquinado. Os materiais utilizados, para desenvolver este trabalho experimental, foram placas compósitas de carbono/epóxido com duas orientações de fibras diferentes: unidireccionais e em “cross-ply”. Não se conseguiu muita informação, junto do fornecedor, das suas características pelo que se levaram a cabo ensaios que permitiram determinar o seu módulo de elasticidade. Relativamente á sua resistência â tração, como já foi referido, a grande resistência oferecida pelo material, associada às limitações da máquina de ensaios não permitiu chegar a valores conclusivos. Foram usadas três geometrias de ferramenta diferentes: helicoidal, Brad e Step. Os materiais utilizados nas ferramentas, foram o aço rápido (HSS) e o carboneto de tungsténio para as brocas helicoidais de 118º de ângulo de ponta e apenas o carboneto de tungsténio para as brocas Brad e Step. As ferramentas em diamante não foram consideradas neste trabalho, pois, embora sejam reconhecidas as suas boas características para a maquinagem de compósitos, o seu elevado custo não justifica a sua escolha, pelo menos num trabalho académico, como é o caso. As vantagens e desvantagens de cada geometria ou material utilizado foram avaliadas, tanto no que diz respeito à delaminação como á resistência mecânica dos provetes ensaiados. Para a determinação dos valores de delaminação, foi usada a técnica de Raio X. Algum conhecimento já existente relativamente a este processo permitiu definir alguns parâmetros (por exemplo: tempo de exposição das placas ao liquido contrastante), que tornaram acessível o procedimento de obtenção de imagens das placas furadas. Importando estas imagens para um software de desenho (no caso – AutoCad), foi possível medir as áreas delaminadas e chegar a valores para o fator de delaminação de cada furo efetuado. Terminado este processo, todas as placas foram sujeitas a ensaios de esmagamento, de forma a avaliar a forma como os parâmetros de maquinagem afectaram a resistência mecânica do material. De forma resumida, são objetivos deste trabalho: - Caracterizar as condições de corte em materiais compósitos, mais especificamente em fibras de carbono reforçado com matriz epóxida (PRFC); - Caracterização dos danos típicos provocados pela furação destes materiais; - Desenvolvimento de análise não destrutiva (RX) para avaliação dos danos provocados pela furação; - Conhecer modelos existentes com base na mecânica da fratura linear elástica (LEFM); - Definição de conjunto de parâmetros ideais de maquinagem com o fim de minimizar os danos resultantes da mesma, tendo em conta os resultados provenientes dos ensaios de força, da análise não destrutiva e da comparação com modelos de danos existentes e conhecidos.

Re-Use Assessment of Thermoset Composite Wastes as Aggregate and Filler Replacement for Concrete-Polymer Composite Materials: A case study regarding GFRP pultrusion wastes

Glass fibre-reinforced plastics (GFRP), nowadays commonly used in the construction, transportation and automobile sectors, have been considered inherently difficult to recycle due to both the cross-linked nature of thermoset resins, which cannot be remoulded, and the complex composition of the composite itself, which includes glass fibres, polymer matrix and different types of inorganic fillers. Hence, to date, most of the thermoset based GFRP waste is being incinerated or landfilled leading to negative environmental impacts and additional costs to producers and suppliers. With an increasing awareness of environmental matters and the subsequent desire to save resources, recycling would convert an expensive waste disposal into a profitable reusable material. In this study, the effect of the incorporation of mechanically recycled GFRP pultrusion wastes on flexural and compressive behaviour of polyester polymer mortars (PM) was assessed. For this purpose, different contents of GFRP recyclates (0%, 4%, 8% and 12%, w/w), with distinct size grades (coarse fibrous mixture and fine powdered mixture), were incorporated into polyester PM as sand aggregates and filler replacements. The effect of the incorporation of a silane coupling agent was also assessed. Experimental results revealed that GFRP waste filled polymer mortars show improved mechanical behaviour over unmodified polyester based mortars, thus indicating the feasibility of GFRP waste reuse as raw material in concrete-polymer composites.

Estudo da Produção de Towpregs e Transformação por Pultrusão

Durante as últimas décadas, os materiais compósitos têm substituído com sucesso os materiais tradicionais em muitas aplicações de engenharia, muito devido às excelentes propriedades que se conseguem obter com a combinação de materiais diferentes. Nos compósitos reforçados com fibras longas ou contínuas tem-se verificado, ao longo dos últimos anos, um aumento do uso de matrizes termoplásticas, fruto de várias vantagens associadas, como o facto de serem bastante mais ecológicas, comparativamente às termoendurecíveis. No entanto, este aumento está muito dependente do desenvolvimento de novas tecnologias de processamento, pois a elevada viscosidade dos termoplásticos, comparativamente aos termoendurecíveis, dificulta significativamente o processo. Muitos equipamentos de produção de termoplásticos são resultado de adaptações de equipamentos de produção de termoendurecíveis, onde normalmente é necessário adicionar fornos de pré-aquecimento. Neste trabalho, pretendeu-se produzir pré-impregnados de fibras contínuas com matriz termoplástica, por deposição a seco de polímero em pó sobre fibras de reforço (denominados por towpreg) para, posteriormente, serem transformados por pultrusão e caracterizados. As matérias-primas utilizadas foram: Polipropileno (PP) como matriz termoplástica e fibra de carbono como reforço. Por forma a melhorar as propriedades finais do compósito, foram otimizadas as condições de processamento na produção dos towpregs, estudando-se a influência da variação dos parâmetros de processamento no teor de polímero presente nestes, tendo como objetivo teores mássicos de polímero superiores a 30%. A condição ótima e a influência dos parâmetros de processamento foram obtidas com o auxílio do Método de Taguchi. Os perfis produzidos por pultrusão foram sujeitos a ensaios de flexão, de forma a obter as suas propriedades quando sujeitos a esse tipo de esforço. Foram também realizados ensaios de calcinação de forma a obter as frações mássicas de fibra e polímero presentes no compósito final. Sabidas as frações mássicas, converteramse em frações volúmicas e obtiveram-se as propriedades teoricamente esperadas através da Lei das Misturas e compararam-se com as obtidas experimentalmente. As propriedades obtidas foram também comparadas com as de outros compósitos pultrudidos.

Evaluation of tools and cutting conditions on carbon fibre reinforced laminates

The distinctive characteristics of carbon fibre reinforced plastics, like low weight or high specific strength, had broadened their use to new fields. Due to the need of assembly to structures, machining operations like drilling are frequent. In result of composites inhomogeneity, this operation can lead to different damages that reduce mechanical strength of the parts in the connection area. From these damages, delamination is the most severe. A proper choice of tool and cutting parameters can reduce delamination substantially. In this work the results obtained with five different tool geometries are compared. Conclusions show that the choice of an adequate drill can reduce thrust forces, thus delamination damage.

Experimental study on polyester based concretes filled with glass fibre reinforced plastic recyclates – a contribution to composite materials sustainability

The development and applications of thermoset polymeric composites, namely fibre reinforced plastics (FRP), have shifted in the last decades more and more into the mass market [1]. Despite of all advantages associated to FRP based products, the increasing production and consume also lead to an increasing amount of FRP wastes, either end-of-lifecycle products, or scrap and by-products generated by the manufacturing process itself. Whereas thermoplastic FRPs can be easily recycled, by remelting and remoulding, recyclability of thermosetting FRPs constitutes a more difficult task due to cross-linked nature of resin matrix. To date, most of the thermoset based FRP waste is being incinerated or landfilled, leading to negative environmental impacts and supplementary added costs to FRP producers and suppliers. This actual framework is putting increasing pressure on the industry to address the options available for FRP waste management, being an important driver for applied research undertaken cost efficient recycling methods. [1-2]. In spite of this, research on recycling solutions for thermoset composites is still at an elementary stage. Thermal and/or chemical recycling processes, with partial fibre recovering, have been investigated mostly for carbon fibre reinforced plastics (CFRP) due to inherent value of carbon fibre reinforcement; whereas for glass fibre reinforced plastics (GFRP), mechanical recycling, by means of milling and grinding processes, has been considered a more viable recycling method [1-2]. Though, at the moment, few solutions in the reuse of mechanically-recycled GFRP composites into valueadded products are being explored. Aiming filling this gap, in this study, a new waste management solution for thermoset GFRP based products was assessed. The mechanical recycling approach, with reduction of GFRP waste to powdered and fibrous materials was applied, and the potential added value of obtained recyclates was experimentally investigated as raw material for polyester based mortars. The use of a cementless concrete as host material for GFRP recyclates, instead of a conventional Portland cement based concrete, presents an important asset in avoiding the eventual incompatibility problems arisen from alkalis silica reaction between glass fibres and cementious binder matrix. Additionally, due to hermetic nature of resin binder, polymer based concretes present greater ability for incorporating recycled waste products [3]. Under this scope, different GFRP waste admixed polymer mortar (PM) formulations were analyzed varying the size grading and content of GFRP powder and fibre mix waste. Added value of potential recycling solution was assessed by means of flexural and compressive loading capacities of modified mortars with regard to waste-free polymer mortars.

Layer-by-layer immobilization of carbon dots fluorescent nanomaterials on single optical fiber

We report within this paper the development of a fiber-optic based sensor for Hg(II) ions. Fluorescent carbon nanoparticles were synthesized by laser ablation and functionalized with PEG200 and N-acetyl-l-cysteine so they can be anionic in nature. This characteristic facilitated their deposition by the layer-by-layer assembly method into thin alternating films along with a cationic polyelectrolyte, poly(ethyleneimine). Such films could be immobilized onto the tip of a glass optical fiber, allowing the construction of an optical fluorescence sensor. When immobilized on the fiber-optic tip, the resultant sensor was capable of selectively detecting sub-micromolar concentrations of Hg(II) with an increased sensitivity compared to carbon dot solutions. The fluorescence of the carbon dots was quenched by up to 44% by Hg(II) ions and interference from other metal ions was minimal.

Novel potentiometric sensors of molecular imprinted polymers for specific binding of chlormequat

Molecularly imprinted polymers (MIP) were used as potentiometric sensors for the selective recognition and determination of chlormequat (CMQ). They were produced after radical polymerization of 4-vinyl pyridine (4-VP) or methacrylic acid (MAA) monomers in the presence of a cross-linker. CMQwas used as template. Similar nonimprinted (NI) polymers (NIP) were produced by removing the template from reaction media. The effect of kind and amount of MIP or NIP sensors on the potentiometric behavior was investigated. Main analytical features were evaluated in steady and flow modes of operation. The sensor MIP/4-VP exhibited the best performance, presenting fast near-Nernstian response for CMQover the concentration range 6.2×10-6 – 1.0×10-2 mol L-1 with detection limits of 4.1×10-6 mol L-1. The sensor was independent from the pH of test solutions in the range 5 – 10. Potentiometric selectivity coefficients of the proposed sensors were evaluated over several inorganic and organic cations. Results pointed out a good selectivity to CMQ. The sensor was applied to the potentiometric determination of CMQin commercial phytopharmaceuticals and spiked water samples. Recoveries ranged 96 to 108.5%.

Biomimetic sensors of molecularly-imprinted polymers for chlorpromazine determination

A new man-tailored biomimetic sensor for Chlorpromazine host-guest interactions and potentiometric transduction is presented. The artificial host was imprinted within methacrylic acid, 2-vinyl pyridine and 2-acrylamido-2-methyl-1-propanesulfonic acid based polymers. Molecularly imprinted particles were dispersed in 2-nitrophenyloctyl ether and entrapped in a poly(vinyl chloride) matrix. Slopes and detection limits ranged 51–67 mV/decade and 0.46–3.9 μg/mL, respectively, in steady state conditions. Sensors were independent fromthe pHof test solutionswithin 2.0–5.5.Good selectivitywas observed towards oxytetracycline, doxytetracycline, ciprofloxacin, enrofloxacin, nalidixic acid, sulfadiazine, trimethoprim, glycine, hydroxylamine, cysteine and creatinine. Analytical features in flowing media were evaluated on a double-channel manifold, with a carrier solution of 5.0×10−2 mol/L phosphate buffer. Near-Nernstian response was observed over the concentration range 1.0×10−4 to 1.0×10−2 mol/L. Average slopes were about 48 mV/decade. The sensors were successfully applied to field monitoring of CPZ in fish samples, offering the advantages of simplicity, accuracy, automation feasibility and applicability to complex samples.

New sensing materials of molecularly-imprinted polymers for the selective recognition of Chlortetracycline

As a result of the stressful conditions in aquaculture facilities there is a high risk of bacterial infections among cultured fish. Chlortetracycline (CTC) is one of the antimicrobials used to solve this problem. It is a broad spectrum antibacterial active against a wide range of Gram-positive and Gram-negative bacteria. Numerous analytical methods for screening, identifying, and quantifying CTC in animal products have been developed over the years. An alternative and advantageous method should rely on expeditious and efficient procedures providing highly specific and sensitive measurements in food samples. Ion-selective electrodes (ISEs) could meet these criteria. The only ISE reported in literature for this purpose used traditional electro-active materials. A selectivity enhancement could however be achieved after improving the analyte recognition by molecularly imprinted polymers (MIPs). Several MIP particles were synthesized and used as electro-active materials. ISEs based in methacrylic acid monomers showed the best analytical performance according to slope (62.5 and 68.6 mV/decade) and detection limit (4.1×10−5 and 5.5×10−5 mol L−1). The electrodes displayed good selectivity. The ISEs are not affected by pH changes ranging from 2.5 to 13. The sensors were successfully applied to the analysis of serum, urine and fish samples.

Trimethoprim-selective electrodes with molecularly imprinted polymers acting as ionophores and potentiometric transduction on graphite solid-contact

This work proposes a new biomimetic sensor material for trimethoprim. It is prepared by means of radical polymerization, having trimethylolpropane trimethacrylate as cross-linker, benzoyl peroxide as radicalar iniciator, chloroform as porogenic solvent, and methacrylic acid and 2-vinyl pyridine as monomers. Different percentages of sensor in a range between 1 and 6% were studied. Their behavior was compared to that obtained with ion-exchanger quaternary ammonium salt (additive tetrakis(p-chlorophenyl)borate or tetraphenylborate). The effect of an anionic additive in the sensing membrane was also tested. Trimethoprim sensors with 1% of imprinted particles from methacrylic acid monomers showed the best response in terms of slope (59.7 mV/decade) and detection limit (4.01×10−7 mol/L). These electrodes displayed also a good selectivity towards nickel, manganese aluminium, ammonium, lead, potassium, sodium, iron, chromium, sulfadiazine, alanine, cysteine, tryptophan, valine and glycine. The sensors were not affected by pH changes from 2 to 6. They were successfully applied to the analysis of water from aquaculture.