"Industrial applications of Composite Polymers" by Oan

Oan Muhammad

Topic:

Industrial applications of composites

Oan.sahito@gmail.com

Presented By:

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•COMPOSITE POLYMERS•NATURAL COMPOSITES•INDUSTRIAL COMPOSITES•TYPES OF COMPOSITES•COMPOSITES IN ENGINEERING•ADVANTAGES•INDUSTRY IN PAKISTAN•CONCLUSION

OBJECTIVES

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COMPOSITE POLYMERS

ASPHALT CEMENT

PLYWOOD FIBER GLASS

Two or more chemically or physically distinct materials which when combined have improved properties over the individual materials. Composites could be natural or synthetic.

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TR A D ITIO N A L/N ATU R A L C O M P O S ITES

Co m p o s i t e m a te r i a l s t h a t o ccu r i n n a tu r e o r h a v e b een p r o d u c ed b y c iv i l i z a t i o n s f o r m an y y ea r s .

E x a m p le s : Wo o d , Co n c r e t e , A sp h a l t

S Y N TH ETIC C O M P O S ITES

Mo d er n m a te r i a l sy s t e m s n o r m a l ly a s so c i a t ed w i th t h e m a n u f ac tu r in g in d u s t r i e s , I n w h ich th e co m p o n en t s a r e f i r s t p r o d u c ed s ep a r a t e ly an d t h en c o m b in ed i n a c o n t r o l l ed w ay to ac h i ev e t h e d e s i r ed s t r u c tu r e , p r o p e r t i e s , an d p a r t g eo m e t r y .

Possible Classification of Composite Materials

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1. BO N E

2. W O O D

3. A S P H A LT

4. BRI CK S

5. CO N CRE T E

Traditional/Natural composites

1. Aircraft2. Boats and Ships3. Sport equipment

(Golf shafts, tennis rackets, surfboards, hokey sticks, etc.)

4. Automotive components5. Body armor6. Building materials7. Water pipes8. Bridges9. Tool handles10. Ladder rails

IndustrialComposites

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Bone as a Composite

COLLAGEN

The Bone in our body is a composite. It is made from a hard and brittle material called Hydroxyapatite (which is mainly calcium phosphate) and a soft and flexible material called collagen (which is a protein).

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Wood as a Composite

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•Wood consists of cellulose, hemicellulose & lignin•Cellulose-the strongest component, 65% unidirectional alignment•Lignin behave as adhesive, tighten the wood components

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Bricks as a Composite

The combination of mud and straw forms a composite that is stronger than either the mud or the straw by itself.

MUD/CLAY

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Concrete as a Composite

Concrete is a mixture of

aggregate (small stones or

gravel), cement and sand. It

has good compressive

strength. In more recent times it has been

found that adding metal rods or

wires to the concrete can increase

its tensile (bending) strength.

Concrete containing such rods or

wires is called reinforced

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Industrial Applications

A wide variety of composite products are used in industrial applications, where corrosion resistance and performance in adverse environments is critical. Generally, premium resins such as isophthalic and vinyl ester formulations are required to meet corrosion resistance specifications, and fiberglass is almost always used as the reinforcing fiber. Industrial composite products include underground storage tanks, scrubbers, piping, fume hoods, water treatment components, pressure vessels, and a host of other products.

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Isophthalic Vinyl Ester

Isophthalic & Vinyl Ester

Isophthalic acid is a non-toxic, colorless crystalline solid that is used to make simple esters widely used as plasticizers

Vinylester, is a resin produced by the esterification of an epoxy resin with an unsaturated mono-carboxylic acid.

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Modern composi tes are f iberglass , in troduced in 1940s, which is widely used to form large l ightweight re inforced s tructures such as body of corvet te or hul l of cabin cruiser or as a l ternat ive in heavy porcelain in manufacture of bathtubs and shower s ta l ls .

FIBERGLASS

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Metal Matrix Composites

The metal matrix composites offer higher modulus of elasticity, ductility and resistance to elevated temperature than polymer matrix composites. But they are heavier and more difficult to process.

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Composites In Civil Engineering

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Composites have long been used in the construction industry. Applications range from non-structural gratings and claddings to full structural systems for industrial supports, buildings, long span roof structures, tanks, bridge components and complete bridge systems.

FRP (Fiber Reinforced) is used in structural shapes, repair materials or as reinforcement for concrete.

Polyseters : Used for FRP components(inexpensive &easy)Vinylesters: Alkali resistance, reduced moisture & shrinkageEpoxies : For adhesion and bonding

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Composites in Automotive Engineering

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Application Material Processing MethodLoad-Bearing- bumper beams

Glass-fiber reinforced polyester resins

Pressing of resincompounds

Moldings/covers- front apron- spoiler- wheel-well liners- radiator grill- hood- fenders- trunk

PolyurathanePolypropylenePolyethleneAcrylonitrile-butadiene- styrene (ABS)Polycarbonate

Injection Molding

ProtectiveMoldings

Polyvinyl chlorideEthylene-PropyleneTerpolymers

Injection Molding/Extrusion

EnergyAbsorbing Foam

Polyurethane Liquid ReactionFoaming

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COMPOSITES IN AEROSPACE

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MAJOR INDUSTRIAL COMPOSITES IN

PAKISTAN

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Other major industries include cement, fertilizer, automobile, sugar, tobacco, chemicals, light engineering, defense production, food processing, ship manufacturing and ship breaking industry.

Cotton, textile production and apparel manufacturing are Pakistan's largest industries, accounting for about 66% of the merchandise exports and almost 40% of the employed labour force.

Pakistan ranks 55th worldwide in factory output.

Pakistan's industrial sector accounts for about 24% of GDP.

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There are 4 heavy Engineering Industries in public sector

(1) Heavy Mechanical Complex, Taxila

(2) Pakistan Machine Tools Factory, Landhi

(3) Pakistan Ordinance Factory Wah

(Defense Production)

(4) Karachi Shipyard & Engineering Works Karachi

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Advantages

•Higher Specific Strength (strength-to-weight ratio)

•Design flexibility

•Corrosion Resistance

•Durability

•Low Relative Investment

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Conclusion

The primary driver and advantage in the adoption of composites is the

lightweight properties. In transportation, less weight equates to more fuel savings

and improved acceleration.

In sporting equipment, lightweight composites allow for longer drives in golf,

faster swings in tennis, and straighter shots in archery.

While in wind energy, the less a blade weighs, the more power the turbine can

produce.

Besides weight savings, the most important benefits of composites include:

Non-corrosive, Non-conductive, Flexible, will not Dent, Low Maintenance, Long

Life, Design flexibility.

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S P EC IA L TH A N K S TO A LM IG H TY A LLA H ,

M Y PA R EN TS A N D M Y FA M ILY .

I A C K N O W LED G E TH IS W O R K TO

P RO F. D R. S H AH ABU D D IN MEMO N F O R K IN D S U P ERV IS IO N & G U ID E IN LIF E A S PEC TS .

I A M V ERY TH A N K F U L TO A LL M Y F R IEN D S A N D C LA S S M ATES W H O A LWAY S G IV E M E R ES P EC T

A N D SU P P O RT

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Acknowledgements

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THANK YOU