Recyclable Short Fibre Reinforced Plastics PP/Nylon and HDPE/Nylon composites

The study shows that standard plastics like polypropylene and high density polyethylene can be reinforced by adding nylon short fibres. Compared to the conventional glass reinforced thermoplastics this novel class of reinforced thermoplastics has the major advantage of recyclability. Hence such composites represent a new spectrum of recyclable polymer composites. The fibre length and fibre diameter used for reinforcement are critical parameters While there is a critical fibre length below which no effective reinforcement takes place, the reinforcement improves when the fibre diameter decreases due to increased surface area.While the fibres alone give moderate reinforcement, chemical modification of the matrix can further improve the strength and modulus of the composites. Maleic anhydride grafting in presence of styrene was found to be the most efficient chemical modification. While the fibre addition enhances the viscosity of the melt at lower shear rates, the enhancement at higher shear rate is only marginal. This shows that processing of the composite can be done in a similar way to that of the matrix polymer in high shear operations such as injection moulding. Another significant observation is the decrease in melt viscosity of the composite upon grafting. Thus chemical modification of matrix makes processing of the composite easier in addition to improving the mechanical load bearing capacity.For the development of a useful short fibre composite, selection of proper materials, optimum design with regard to the particular product and choosing proper processing parameters are most essential. Since there is a co-influence of many parameters, analytical solutions are difficult. Hence for selecting proper processing parameters 'rnold flow' software was utilized. The orientation of the fibres, mechanical properties, temperature profile, shrinkage, fill time etc. were determined using the software.Another interesting feature of the nylon fibre/PP and nylon fibre/HDPE composites is their thermal behaviour. Both nylon and PP degrade at the same temperature in single steps and hence the thermal degradation behaviour of the composites is also being predictable. It is observed that the thermal behaviour of the matrix or reinforcement does not affect each other. Almost similar behaviour is observed in the case of nylon fibre/HDPE composites. Another equally significant factor is the nucleating effect of nylon fibre when the composite melt cools down. In the presence of the fibre the onset of crystallization occurs at slightly higher temperature.When the matrix is modified by grafting, the onset of crystallization occurs at still higher temperature. Hence it may be calculated that one reason for the improvement in mechanical behaviour of the composite is the difference in crystallization behaviour of the matrix in presence of the fibre.As mentioned earlier, a major advantage of these composites is their recyclability. Two basic approaches may be employed for recycling namely, low temperature recycling and high temperature recycling. In the low temperature recycling, the recycling is done at a temperature above the melting point of the matrix, but below that of the fibres while in the high temperature route. the recycling is done at a temperature above the melting points of both matrix and fibre. The former is particularly interesting in that the recycled material has equal or even better mechanical properties compared to the initial product. This is possible because the orientation of the fibre can improve with successive recycling. Hence such recycled composites can be used for the same applications for which the original composite was developed. In high temperature recycling, the composite is converted into a blend and hence the properties will be inferior to that of the original composite, but will be higher than that of the matrix material alone.

Studies on the fracture behaviour of polymer blends with special reference to PP/HDPE and PS/HIPS blends

Investigations on the fracture behaviour of polymer blends is the topic of this thesis. The blends selected are PP/HDPE and PS/HIPS. PP/HDPE blend is chosen due to its commercial importance and PS/HIPS blend is selected to study the transition from brittle fracture to ductile fracture.PP/HDPE blends were prepared at different compositions by melt blending at 180°C and fracture failure process was investigated by conducting notch sensitivity test and tensile test at different strain rates. The effects of two types of modifiers (particulate and elastomer) on the fracture behaviour and notch sensitivity of PP/HDPE blends were studied. The modifiers used are calcium carbonate, a hard particulate filler commonly used in plastics and Ethylene Propylene Diene Monomer (EPDM). They were added in 2%, 4% and 6% by weight of the blends.The study shows that the mechanical properties of PP/HDPE blends can be optimized by selecting proper blend compositions. The selected modifiers are found to alter and improve the fracture behaviour and notch sensitivity of the blends. Particulate fillers like calcium carbonate can be used for making the mechanical behaviour more stable at the various blend compositions. The resistance to notch sensitivity of the blends is found to be marginally lower in the presence of calcium carbonate. The elastomeric modifier EPDM produces a better stability of the mechanical behaviour. A low concentration of EPDM is sufficient to effect such a change. EPDM significantly improves the resistance to notch sensitivity of the blends. The study shows that judicious selection of modifiers can improve the fracture behaviour and notch sensitivity of PP/HDPE blends and help these materials to be used for critical applications.For investigating the transition in fracture behaviour and failure modes, PS/HIPS blends were selected. The blends were prepared by melt mixing followed by injection moulding to prepare the specimens for conducting tensile, impact and flexure tests. These tests were used to simulate the various conditions which promote failure.The tensile behaviour of unnotched and notched PS/HIPS blend samples were evaluated at slow speeds. Tensile strengths and moduli were found to increase at the higher testing speed for all the blend combinations whereas maximum strain at break was found to decrease. For a particular speed of testing, the tensile strength and modulus show only a very slight decrease as HIPS content is increased up to about 40%. However, there is a drastic decrease on increasing the HIPS content thereafter.The maximum strain at break shows only a very slight change up to about 40% HIPS content and thereafter shows a remarkable increase. The notched specimens also follow a comparable trend even though the notch sensitivity is seen high for PS rich blends containing up to 40% HIPS. The notch sensitivity marginally decreases with increase in HIPS content. At the same time, it is found to increase with the increase in strain rate. It is observed that blends containing more than 40% HIPS fail in ductile mode.The impact characteristics of PSIHIPS blends studied were impact strength, the energy absorbed by the test specimen and impact toughness. Remarkable increase in impact strength is observed as HIPS content in the blend exceeds 40%. The energy absorbed by the test specimens and the impact toughness also show a comparable trend.Flexural testing which helps to characterize the load bearing capacity was conducted on PS/HIPS blend samples at the two different testing speeds of 5mmlmin and 10 mm/min. The flexural strength increases with increase in testing speed for all the blend compositions. At both the speeds, remarkable reduction in flexural strength is observed as HIPS content in the blend exceeds 40%. The flexural strain and flexural energy absorbed by the specimens are found to increase with increase in HIPS content. At both the testing speeds, brittle fracture is observed for PS rich blends whereas HIPS rich blends show ductile mode of failure.Photoelastic investigations were conducted on PS/HIPS blend samples to analyze their failure modes. A plane polariscope with a broad source of light was utilized for the study. The coloured isochromatic fringes formed indicate the presence of residual stress concentration in the blend samples. The coverage made by the fringes on the test specimens varies with the blend composition and it shows a reducing trend with the increase in HIPS content. This indicates that the presence of residual stress is a contributing factor leading to brittle fracture in PS rich blends and this tendency gradually falls with increase in HIPS content and leads to their ductile mode of failure.

Utilisation of Coir Geotextiles for Unpaved Roads and Embankments

The increasing tempo of construction activity the world over creates heavy pressure on existing land space. The quest for new and competent site often points to the needs for improving existing sites, which are otherwise deemed unsuitable for adopting conventional foundations. This is accomplished by ground improvement methods, which are employed to improve the quality of soil incompetent in their natural state. Among the construction activities, a well-connected road network is one of the basic infrastructure requirements, which play a vital role for the fast and comfortable movement of inter- regional traffic in countries like India.One of the innovative ground improvement techniques practised all over the world is the use of geosynthetics, which include geotextiles, geomembranes, geogrids, etc . They offer the advantages such as space saving, enviromnental sensitivity, material availability, technical superiority, higher cost savings, less construction time, etc . Because of its fundamental properties, such as tensile strength, filtering and water permeability, a geotextile inserted between the base material and sub grade can function as reinforcement, a filter medium, a separation layer and as a drainage medium. Though polymeric geotextiles are used in abundant quantities, the use of natural geotextiles (like coir, jute, etc.) has yet to get momentum. This is primarily due to the lack of research work on natural geotextilcs for ground improvement, particularly in the areas of un paved roads. Coir geotextiles are best suited for low cost applications because of its availability at low prices compared to its synthetic counterparts. The proper utilisation of coir geotextilcs in various applications demands large quantities of the product, which in turn can create a boom in the coir industry. The present study aims at exploring the possibilities of utilising coir geotextiles for unpaved roads and embankments.The properties of coir geotextiles used have been evaluated. The properties studied include mass per unit area, puncture resistance, tensile strength, secant modulus, etc . The interfacial friction between soils and three types of coir geotextiles used was also evaluated. It was found that though the parameters evaluated for coir geotextiles have low values compared to polymeric geotextiles, the former are sufficient for use in unpaved roads and embankments. The frictional characteristics of coir geotextile - soil interfaces are extremely good and satisfy the condition set by the International Geosynthetic Society for varied applications.The performance of coir geotextiles reinforced subgrade was studied by conducting California Bearing Ratio (CBR) tests. Studies were made with coir geotextiles placed at different levels and also in multiple layers. The results have shown that the coir geotextile enhances the subgrade strength. A regression analysis was perfonned and a mathematical model was developed to predict the CBR of the coir geotextile reinforced subgrade soil as a function of the soil properties, coir geotextile properties, and placement depth of reinforcement.The effects of coir geotextiles on bearing capacity were studied by perfonning plate load tests in a test tan1e This helped to understand the functioning of geotextile as reinforcement in unpaved roads and embankments. The perfonnance of different types of coir geotextiles with respect to the placement depth in dry and saturated conditions was studied. The results revealed that the bearing capacity of coir-reinforced soil is increasing irrespective of the type of coir geotextiles and saturation condition.The rut behaviour of unreinforced and coir reinforced unpaved road sections were compared by conducting model static load tests in a test tank and also under repetitive loads in a wheel track test facility. The results showed that coir geotextiles could fulfill the functions as reinforcement and as a separator, both under static and repetitive loads. The rut depth was very much reduced whik placing coir geotextiles in between sub grade and sub base.In order to study the use of Coir geotextiles in improving the settlement characteristics, two types of prefabricated COlf geotextile vertical drains were developed and their time - settlement behaviour were studied. Three different dispositions were tried. It was found that the coir geotextile drains were very effective in reducing consolidation time due to radial drainage. The circular drains in triangular disposition gave maximum beneficial effect.In long run, the degradation of coir geotextile is expected, which results in a soil - fibre matrix. Hence, studies pertaining to strength and compressibility characteristics of soil - coir fibre composites were conducted. Experiments were done using coir fibres having different aspect ratios and in different proportions. The results revealed that the strength of the soil was increased by 150% to 200% when mixed with 2% of fibre having approximately 12mm length, at all compaction conditions. Also, the coefficient of consolidation increased and compression index decreased with the addition of coir fibre.Typical design charts were prepared for the design of coir geotextile reinforced unpaved roads. Some illustrative examples are also given. The results demonstrated that a considerable saving in subase / base thickness can he achieved with the use of eoir geotextiles, which in turn, would save large quantities of natural aggregates.

A Study on the Engineering Behaviour of Grouted Loose Soils

The constructional activities in the coastal belt of our country often demand deep foundations because of the poor engineering properties and the related problems arising from weak soil at shallow depths.The soil profile in coastal area often consists of very loose sandy soils extending to a depth of 3 to 4 m from the ground level underlain by clayey soils of medium consistency.The very low shearing resistance of the foundation bed causes local as well as punching shear failure.Hence structures built on these soils may suffer from excessive settlements.This type of soil profile is very common in coastal areas of Kerala,especially in Cochin. Further,the high water table and limited depth of the top sandy layer in these areas restrict the depth of foundation thereby further reducing the safe bearing capacity.

Settlement Of Reinforced Sand In Foundations

The technique of reinforcing soil for foundation improvement is well established. This paper addresses the aspect of settlement of reinforced sand foundations, where the major part of the existing work deals with the aspect of bearing capacity. A detailed analysis is made paying individual attention to soil, reinforcement, and the interface between the two. A three-dimensional, nonlinear finite-element analysis is presented that uses a three-dimensional, nonlinear soil-reinforcement interface friction element, along with other threedimensional elements to model the system. The results of the analysis are compared with those from tests conducted in the laboratory and are found to be in good agreement. The studies lead to a better understanding of the behavior of the system at different stages of loading

A Comparative Study Of Tensile And Microstructural Characteristics Of Friction Welded Joints And Conventionally Welded Joints Of Aluminium Alloy 6061

Welding of high strength and low weight materials like Aluminium Alloys without any defects by conventional welding techniques is a major challenge in industries. Hence research on solid state welding techniques like Friction stir welding and Friction welding techniques have got much importance in joining of Aluminium alloys. However most of the industries are not changing conventional techniques as skilled workers are available on that area. Most common conventional welding techniques used for joining of Aluminium alloys are Gas welding and Arc welding. Friction welding is a solid-state welding process that generates heat through mechanical friction between a moving and a stationary component with the addition of a lateral force called “upset” to plast ically displace and fuse the materials. In this work, experimental study on tensile and micro structural characteristics of welded joints formed from conventional welding techniques and Rotary friction welding(suitable for weld specimens with circular cross section) has been carried out and the same were compared. The process parameters for arc welding used was 50-70 Amp reverse polarity DC and electrodes of 2.3mm diameter. In Gas welding, the parameters were oxy acetylene neural flame at 3200°C and 3mm electrodes . In the case of friction welding an axial pressure loading of 3Mpa with 5 MPa as upsetting pressure and 500 rpm were used to obtain good welded joints. Tensile characteristic studies of Arc welded joints and Gas welded joints showed 48% and 60 % variations respectively from the maximum load bearing characteristics of parent metal. In the case of friction welded joint, the variation was found to 46%. Micro structural evaluation of conventionally welded joints exhibited clear distinct zones of various weld regions. In the case of friction welded joint micro structural photographs showed comparable features both in parent metal and welded region. Thus the tensile characteristic study and microstructure evaluations proved that friction welded joints are good in both aspects compared to conventionally welded joints.

Modification of Polypropylene/High Density Polyethylene Blend Using Nanokaolinite Clay and E-Glass Fibre: Preparation, Characterization and Micromechanical Modelling

Upgrading two widely used standard plastics, polypropylene (PP) and high density polyethylene (HDPE), and generating a variety of useful engineering materials based on these blends have been the main objective of this study. Upgradation was effected by using nanomodifiers and/or fibrous modifiers. PP and HDPE were selected for modification due to their attractive inherent properties and wide spectrum of use. Blending is the engineered method of producing new materials with tailor made properties. It has the advantages of both the materials. PP has high tensile and flexural strength and the HDPE acts as an impact modifier in the resultant blend. Hence an optimized blend of PP and HDPE was selected as the matrix material for upgradation. Nanokaolinite clay and E-glass fibre were chosen for modifying PP/HDPE blend. As the first stage of the work, the mechanical, thermal, morphological, rheological, dynamic mechanical and crystallization characteristics of the polymer nanocomposites prepared with PP/HDPE blend and different surface modified nanokaolinite clay were analyzed. As the second stage of the work, the effect of simultaneous inclusion of nanokaolinite clay (both N100A and N100) and short glass fibres are investigated. The presence of nanofiller has increased the properties of hybrid composites to a greater extent than micro composites. As the last stage, micromechanical modeling of both nano and hybrid A composite is carried out to analyze the behavior of the composite under load bearing conditions. These theoretical analyses indicate that the polymer-nanoclay interfacial characteristics partially converge to a state of perfect interfacial bonding (Takayanagi model) with an iso-stress (Reuss IROM) response. In the case of hybrid composites the experimental data follows the trend of Halpin-Tsai model. This implies that matrix and filler experience varying amount of strain and interfacial adhesion between filler and matrix and also between the two fillers which play a vital role in determining the modulus of the hybrid composites.A significant observation from this study is that the requirement of higher fibre loading for efficient reinforcement of polymers can be substantially reduced by the presence of nanofiller together with much lower fibre content in the composite. Hybrid composites with both nanokaolinite clay and micron sized E-glass fibre as reinforcements in PP/HDPE matrix will generate a novel class of high performance, cost effective engineering material.