Advances in thermoplastic pultruded composites

Pultrusion is a versatile continuous high speed production technology allowing the production of fibre reinforced complex profiles. Thermosetting resins are normally used as matrices in the production of structural constant cross section profiles. Although only recently thermoplastic matrices have been used in long and continuous fibre reinforced composites replacing with success thermosetting matrices, the number of their applications is increasing due to their better ecological and mechanical performance. Composites with thermoplastic matrices offers increased fracture toughness, higher impact tolerance, short processing cycle time and excellent environmental stability. They are recyclable, post-formable and can be joined by welding. The use of long/continuous fibre reinforced thermoplastic matrix composites involves, however, great technological and scientific challenges since thermoplastics present much higher viscosity than thermosettings, which makes much difficult and complex the impregnation of reinforcements and consolidation tasks. In this work continuous fibres reinforced thermoplastic matrix towpregs were produced using equipment developed by the Institute for Polymers and Composites (IPC). The processing of the towpregs was made by pultrusion, in a developed prototype equipment existing in the Engineering School of the Polytechnic Institute of Porto (ISEP). Different thermoplastic matrices and fibres raw-materials were used in this study to manufacture pultruded composites for commercial applications (glass and carbon fibre/ polypropylene) and for advanced markets (carbon fibre/Primospire®). To improve the temperature distribution profile in heating die, different modifications were performed. In order to optimize both processes, towpregs production and pultruded composites profiles were analysed to determine the influence of the most relevant processing arameters in the final properties. The final pultruded composite profiles were submitted to mechanical tests to obtain the relevant properties.

Comportamento de lajes de betão armado pré-fendilhadas e reforçadas à flexão com laminados de CFRP inseridos pré-tensionados

Dissertação de mestrado integrado em Engenharia Civil

L'ús de materials compostos en el reforç intern d'estructures de formigó

L’ús de materials compostos de matriu polimèrica (FRP, Fibre Reinforced Polymer) en el reforç intern d'estructures de formigó

Lujitemuovisen kaavinterän kannatinpalkin suunnittelu

Diplomityössä perehdytään lujitemuovikomposiitteihin sekä niiden valmistusmenetelmiin. Tavoitteena on kehittää lujitemuovinen paperikoneen kaavinterän kannatinpalkkirakenne. Suunniteltavalla tuotteella pyritään korvaamaan perinteisesti teräksestä valmistetut paperikoneiden kaavinterän pidikepalkit paremmin tarkoitukseen sopivalla lujitemuovisella rakenteella sekä parantamaan jo tuotannossa olevan tuotteen ominaisuuksia. Työssä selvitetään tuotteen vaatimukset, joiden pohjalta laaditaan tuotteen vaatimusprofiili ja suoritetaan materiaalinvalinta perustuen ominaisarvovertailuihin. Suunnitteluosiossa tutkitaan eri rakenneratkaisujen soveltuvuutta kohteeseen. Tutkimustulosten perusteella saatiin kattava kuva eri materiaalien soveltuvuudesta kohteeseen sekä kehitettiin rakenneratkaisu, joka täyttää tuotteelta vaaditut ominaisuudet. Tutkimustulosten pohjalta syntyi myös uuden tyyppinen rakenne jolla saavutetaan huomattavaa tilansäästöä perinteisiin rakenneratkaisuihin nähden. Tämän rakenneratkaisun kehitystyötä on tarkoitus jatkaa.

Coatings on Composites

Polymer based composite materials coated with thin layers of wear resistant materials have been proposed as replacements for steel components for certain applications with the advantage of reduced mass. Magnetron sputtered coatings can be successfully deposited on composite materials. Nevertheless there are number of issues which must be addressed such as limited temperature, which the composite can withstand because of the epoxy binder which is used, the adhesion of the coating to the composite and the limited mechanical support, the hard coating can obtain from the relatively soft epoxy. We have investigated the deposition of chromium nitride, titanium carbide and titanium doped DLC coatings on carbon fibre reinforced composites and various polymers. The adhesion of the coatings has been studied by the pull-off adhesion tester. In general, the failure mechanism has been noticed to be due to the cohesive failure for a wide range of conditions. The wear behavior of the coatings has been noticed to be complicated. Wear tests on coated composites have shown that where the reinforcing fibres are near the surface, the composite samples do not perform well due to breakage of the fibres from the polymer matrix. A fibre free surface has been noticed to improve the wear resistance.

Reconstruction of cranial bone defects with fiber-reinforced composite–bioactive glass implants

A cranial bone defect may result after an operative treatment of trauma, infection, vascular insult, or tumor. New biomaterials for cranial bone defect reconstructions are needed for example to mimic the biomechanical properties and structure of cranial bone. A novel glass fiber-reinforced composite implant with bioactive glass particulates (FRC–BG, fiber-reinforced composite–bioactive glass) has osteointegrative potential in a preclinical setting. The aim of the first and second study was to investigate the functionality of a FRC–BG implant in the reconstruction of cranial bone defects. During the years 2007–2014, a prospective clinical trial was conducted in two tertiary level academic institutions (Turku University Hospital and Oulu University Hospital) to evaluate the treatment outcome in 35 patients that underwent a FRC–BG cranioplasty. The treatment outcome was good both in adult and pediatric patients. A number of conventional complications related to cranioplasty were observed. In the third study, a retrospective outcome evaluation of 100 cranioplasty procedures performed in Turku University Hospital between years 2002–2012 was conducted. The experimental fourth study was conducted to test the load-bearing capacity and fracture behavior of FRC–BG implants under static loading. The interconnective bars in the implant structure markedly increased the load-bearing capacity of the implant. A loading test did not demonstrate any protrusions of glass fibers or fiber cut. The fracture type was buckling and delamination. In this study, a postoperative complication requiring a reoperation or removal of the cranioplasty material was observed in one out of five cranioplasty patients. The treatment outcomes of cranioplasty performed with different synthetic materials did not show significant difference when compared with autograft. The FRC–BG implant was demonstrated to be safe and biocompatible biomaterial for large cranial bone defect reconstructions in adult and pediatric patients.

Ein Beitrag zur realitätsnahen Modellierung und Analyse von stahlfaserverstärkten Stahlbeton- und Stahlbetonflächentragwerken

Das Werkstoffverhalten von stahlfaserfreiem bzw. stahlfaserverstärktem Stahlbeton unter biaxialle Druck- Zugbeanspruchung wurde experimentell und theoretisch untersucht. Die Basis der experimentellen Untersuchungen waren zahlreiche Versuche, die in der Vergangenheit an faserfreiem Stahlbetonscheiben zur Bestimmung des Werkstoffverhaltens von gerissenem Stahlbeton im ebenen Spannungszustand durchgeführt wurden. Bei diesen Untersuchungen wurde festgestellt, dass infolge einer Querzugbeanspruchung eine Abminderung der biaxialen Druckfestigkeit entsteht. Unter Berücksichtigung dieser Erkenntnisse sind zur Verbesserung der Werkstoffeigenschaften des Betons, Stahlbetonscheiben aus stahlfaserverstärktem Beton hergestellt worden. Die aus der Literatur bekannten Werkstoffmodelle für Beton sowie Stahlbeton, im ungerissenen und gerissenen Zustand wurden hinsichtlich der in der Vergangenheit ermittelten Materialeigenschaften des Betons bzw. Stahlbetons unter proportionalen sowie nichtproportionalen äußeren Belastungen erklärt und kritisch untersucht. In den frischen Beton wurden Stahlfasern hinzugegeben. Dadurch konnte die Festigkeits- und die Materialsteifigkeitsabminderung infolge Rissbildung, die zur Schädigung des Verbundwerkstoffs Beton führt, reduziert werden. Man konnte sehen, dass der Druckfestigkeitsabminderungsfaktor und insbesondere die zur maximal aufnehmbaren Zylinderdruckfestigkeit gehörende Stauchung, durch Zugabe von Stahlfasern besser begrenzt wird. Die experimentelle Untersuchungen wurden an sechs faserfreien und sieben stahlfaserverstärkten Stahlbetonscheiben unter Druck-Zugbelastung zur Bestimmung des Verhaltens des gerissenen faserfreien und stahlfaserverstärkten Stahlbetons durchgeführt. Die aus eigenen Versuchen ermittelten Materialeigenschaften des Betons, des stahlfaserverstärkten Betons und Stahlbetons im gerissenen Zustand wurden dargelegt und diskutiert. Bei der Rissbildung des quasi- spröden Werkstoffs Beton und dem stahlfaserverstärkten Beton wurde neben dem plastischen Fließen, auch die Abnahme des Elastizitätsmoduls festgestellt. Die Abminderung der aufnehmbaren Festigkeit und der zugehörigen Verzerrung lässt sich nicht mit der klassischen Fließtheorie der Plastizität ohne Modifizierung des Verfestigungsgesetzes erfassen. Es wurden auf elasto-plastischen Werkstoffmodellen basierende konstitutive Beziehungen für den faserfreien sowie den stahlfaserverstärkten Beton vorgeschlagen. Darüber hinaus wurde in der vorliegenden Arbeit eine auf dem elasto-plastischen Werkstoffmodell basierende konstitutive Beziehung für Beton und den stahlfaser-verstärkten Beton im gerissenen Zustand formuliert. Die formulierten Werkstoffmodelle wurden mittels dem in einer modularen Form aufgebauten nichtlinearen Finite Elemente Programm DIANA zu numerischen Untersuchungen an ausgewählten experimentell untersuchten Flächentragwerken, wie scheibenartigen-, plattenartigen- und Schalentragwerken aus faserfreiem sowie stahlfaserverstärktem Beton verwendet. Das entwickelte elasto-plastische Modell ermöglichte durch eine modifizierte effektive Spannungs-Verzerrungs-Beziehung für das Verfestigungsmodell, nicht nur die Erfassung des plastischen Fließens sondern auch die Berücksichtigung der Schädigung der Elastizitätsmodule infolge Mikrorissen sowie Makrorissen im Hauptzugspannungs-Hauptdruckspannungs-Bereich. Es wurde bei den numerischen Untersuchungen zur Ermittlung des Last-Verformungsverhaltens von scheibenartigen, plattenartigen- und Schalentragwerken aus faserfreiem und stahlfaserverstärktem Stahlbeton, im Vergleich mit den aus Versuchen ermittelten Ergebnissen, eine gute Übereinstimmung festgestellt.

Fracture and fatigue of natural fiber-reinforced cementitious composites

This paper presents the results of an experimental study of resistance-curve behavior and fatigue crack growth in cementitious matrices reinforced with eco-friendly natural fibers obtained from agricultural by-products. The composites include: blast furnace slag cement reinforced with pulped fibers of sisal, banana and bleached eucalyptus pulp, and ordinary Portland cement composites reinforced with bleached eucalyptus pulp. Fracture resistance (R-curve) and fatigue crack growth behavior were studied using single-edge notched bend specimens. The observed stable crack growth behavior was then related to crack/microstructure interactions that were elucidated via scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS). Fracture mechanics models were used to quantify the observed crack-tip shielding due to crack-bridging. The implications of the results are also discussed for the design of natural fiber-reinforced composite materials for affordable housing. (C) 2009 Elsevier Ltd. All rights reserved.

Valorization of an Industrial Organosolv-Sugarcane Bagasse Lignin: Characterization and Use as a Matrix in Biobased Composites Reinforced With Sisal Fibers

In the present study, the main focus was the characterization and application of the by-product lignin isolated through an industrial organosolv acid hydrolysis process from sugarcane bagasse, aiming at the production of bioethanol. The sugarcane lignin was characterized and used to prepare phenolic-type resins. The analysis confirmed that the industrial sugarcane lignin is of HGS type, with a high proportion of the less substituted aromatic ring p-hydroxyphenyl units, which favors further reaction with formaldehyde. The lignin-formaldehyde resins were used to produce biobased composites reinforced with different proportions of randomly distributed sisal fibers. The presence of lignin moieties in both the fiber and matrix increases their mutual affinity, as confirmed by SEM images, which showed good adhesion at the biocomposite fiber/matrix interface. This in turn allowed good load transference from the matrix to the fiber, leading to biobased composites with good impact strength (near 500 J m(-1) for a 40 wt% sisal fiber-reinforced composite). The study demonstrates that sugarcane bagasse lignin obtained from a bioethanol plant can be used without excessive purification in the preparation of lignocellulosic fiber-reinforced biobased composites displaying high mechanical properties. Biotechnol. Bioeng. 2010;107: 612-621. (C) 2010 Wiley Periodicals, Inc.

Estudo da viabilidade técnica para a Bolívia de painéis de gesso reforçados com fibra de vidro para paredes internas não portantes

Na construção civil, nos países em desenvolvimento como a Bolívia, continua-se usando técnicas e materiais na execução de paredes, similar a décadas passadas. Os painéis de gesso reforçados com fibra de vidro são uma alternativa de simplificação e agilização na execução das paredes internas não portantes. A presente dissertação objetiva mostrar a viabilidade técnica e econômica dos painéis para paredes internas, na Bolívia; para tanto realizou-se uma avaliação dos recursos disponíveis (gesso), com relação às reservas, produção e custos. A técnica adotada na produção dos painéis é a de pré-mistura, que permite a moldagem dos painéis manual ou mecanicamente com equipamentos simples e de baixo custo. O estudo do compósito de gesso reforçado com fibra de vidro (GRG) foi realizado com gesso brasileiro e com gesso boliviano, verificando-se o seu comportamento mecânico com diferentes teores de fibra de vidro. Verificou-se aumento da resistência a tração na flexão e diminuição da resistência a compressão com o aumento do teor de fibra de vidro. A avaliação do comportamento mecânico dos painéis foi feita através dos ensaios de impacto (corpo mole e corpo duro). Nos ensaios de corpo mole, verificou-se aumento da resistência com o aumento do teor de fibra de vidro. Os teores de 0,75% e 1,5% se mostraram suficientes para que os painéis de GRG satisfaçam os requisitos de desempenho para divisórias internas respectivamente para o gesso brasileiro e boliviano. O comportamento dos painéis nos ensaios de impacto de corpo duro foi satisfatório, tanto para painéis com fibra como para painéis sem fibra de vidro. No estudo preliminar de custos, verificou-se uma redução em torno de 36% para os painéis de GRG em relação às paredes intemas tradicionalmente usadas na Bolívia.

Efeito da adição de fibras da palma do licuri (syagrus coronata) no comportamento físico e mecânico de compósitos de matriz cimentícia

This research was motivated by the requirement of asbestos s replacement in building systems and the need to generate jobs and income in the country side of the state of Bahia, Brazil. The project aimed at using fibers from licuri leaves (syagrus coronata), an abundant palm in the region, to produce composites appropriate for the sustainable production of cement fibre reinforced products in small plants. The composites were produced in laboratory using Portland cement CP-II-F32, sand, water, licuri palm fiber contents of 1.0, 1.5 and 2.0% by weight of binder (two different fiber length) and metakaolin. The latter was chosen as an additional binder for its efficiency to reduce the alkalinity of cementitious matrixes therefore preventing the degradation of vegetable fibers. The characterization of the composite components was carried out by sieving and laser particle size analyses, thermal analysis, fluorescence and X-ray diffraction. The composites performance was evaluated by 3- point-bending tests, compressive strength, ultrasound module of elasticity, free and restrained shrinkage, water capillarity absorption and apparent specific gravity. It has been found that the addition of fibers increased the time to onset of cracking over 200.00% and a 25% reduction in cracks opening in the restrained shrinkage test. The capillary absorption reduced about 25% when compared to fiber-free composites. It was also observed with regard to flexural strength, compressive strength and specific gravity, that the addiction of fibers did not affect the composite performance presenting similar results for compounds with and without fibers. In general it can be stated that the reinforced composite fibers of palm licuri presents physical and mechanical characteristics which enable them to be used in the intended proposals of this research

Estudo comparativo das propriedades mecânicas em compósitos da fibra modal e poliester

In the present work, three composites with distinct reinforcements (polyester, modal e polyester + modal), all if a unsaturated orthophthalic polyester resin as matrix were used, in order to conduct a comparative study by mechanical tests and water absorption. The fibre mats were prepared in a mat preparatory by immersion developed in the Textile Engineering Laboratory. The composites were manufactured using a closed mould process by compression using an unsaturated orthophthalic polyester resin as matrix and 1% MEK (methyl ethyl ketone peroxide) as an initiator. In each composite twelve samples with the dimensions of 150x25x3 mm were cut randomly for the mechanical analysis (tension x extension, three points bending and water absorption and Scanning Electron Micsroscopy). The mechanical tests were carried out in the Laboratório de Metais e Ensaios Mecânicos UFRN . All the analyses were carried out according to the ASTM norms. The resultant samples from the mechanical analysis were subjected for the Scanning Electron Microscopy analysis. Based on the results obtained, it was observed that the reinforced composite with two fibres (modal + polyester) presented better results in comparison to the other two composites both in the tension/extension as well on the three point bending tests. In the water absorption test, it was possible to observe an equilibrium in the water absorption by the modal and polyester composite, due to the union of the two fibres. In the SEM images, the regions of rupture in the composites as well as the adsorption between the fiber and the matrix could be observed

Mechanical behaviour of self-compacting concrete with hybrid fibre reinforcement

In this study, fibre-reinforced self-compacting concretes were developed for precast building components, incorporating either adherent metal fibres or polymeric synthetic slipping fibres or a combination of both. To achieve the warranted workability, compressive and splitting tensile strengths, compositions were determined by preliminary tests on self-compacting materials with various proportions of metal fibres. Bending tests in controlled deflection confirmed the positive contribution of fibres in the mechanical behaviour of self-compacting concrete. The comparison between vibrated and self-compacting concretes of similar mechanical characteristics indicated a possible better fibre-matrix bond in the case of self-compacting types. The results also showed that the properties of the hybrid fibre-reinforced self-compacting concrete could be inferred from the properties of the individual single-fibre reinforcements and their respective proportions through simple mix-rules.

Unsaturated polyester based composites reinforced with curauá fiber - Preliminary studies

Curauá fiber processing characterization has been performed throughout the different processing steps. Unsaturated polyester has been used as matrix in the production of curauá reinforced composite samples. Compression molding process has been used to prepare the samples. Tensile strength, impact resistance, flexural strength, Young's modulus and elongation at break have been accessed for curauá composites in comparison with fiberglass composites. Mechanical properties were found not to attend the company's internal standards specification. However, the work has shown some alternatives to solve these problems such as the modification of equipment characteristics and resin formulation, the necessity of incorporation of a higher content of fiber and the possibility of using a new type of filler. Copyright © 2000 Society of Automotive Engineers, Inc.

Effect of random/aligned nylon-6/MWCNT fibers on dental resin composite reinforcement

The aims of this study were (1) to synthesize and characterize random and aligned nanocomposite fibers of multi-walled carbon nanotubes (MWCNT)/nylon-6 and (2) to determine their reinforcing effects on the flexural strength of a dental resin composite.Nylon-6 was dissolved in hexafluoropropanol (10 wt%), followed by the addition of MWCNT (hereafter referred to as nanotubes) at two distinct concentrations (i.e., 0.5 or 1.5 wt%). Neat nylon-6 fibers (without nanotubes) were also prepared. The solutions were electrospun using parameters under low- (120 rpm) or high-speed (6000 rpm) mandrel rotation to collect random and aligned fibers, respectively. The processed fiber mats were characterized by scanning (SEM) and transmission (TEM) electron microscopies, as well as by uni-axial tensile testing. To determine the reinforcing effects on the flexural strength of a dental resin composite, bar-shaped (20 x 2 x 2 mm(3)) resin composite specimens were prepared by first placing one increment of the composite, followed by one strip of the mat, and one last increment of composite. Non-reinforced composite specimens were used as the control. The specimens were then evaluated using flexural strength testing. SEM was done on the fractured surfaces. The data were analyzed using ANOVA and the Tukey's test (alpha=5%).Nanotubes were successfully incorporated into the nylon-6 fibers. Aligned and random fibers were obtained using high- and low-speed electrospinning, respectively, where the former were significantly (p<0.001) stronger than the latter, regardless of the nanotubes'presence. Indeed, the dental resin composite tested was significantly reinforced when combined with nylon-6 fibrous mats composed of aligned fibers (with or without nanotubes) or random fibers incorporated with nanotubes at 0.5 wt%. (C) 2015 Elsevier Ltd. All rights reserved.