Manufacturing of polymer composites / B.T. Åström.

Includes bibliographical references and index.

Table of Contents Preface Acknowledgements Nomenclature Abbreviations and Acronyms 1: INTRODUCTION 1.1 The Evolution of Materials 1.2 The Composite Concept 1.3 Design and Manufacturing 1.4 Market 1.5 Application Examples 1.5.1 Transportation Applications 1.5.2 Marine Applications 1.5.3 Aerospace and Military Applications 1.5.4 Construction Applications 1.5.5 Electrical and Sanitary Applications 1.5.6 Sports Applications 1.5.7 Other Applications 1.6 Book Contents 1.7 Outlook 1.8 Summary References 2: CONSTITUENT MATERIALS 2.1 Matrices 2.1.1 Polymer Morphology 2.1.2 Structural Aspects Influencing Properties 2.1.2.1 Intramer Structure 2.1.2.2 Intramolecular Structure 2.1.2.3 Intermolecular Structure 2.1.3 Polymer Properties 2.1.3.1 Thermal Properties of Solid Polymers 2.1.3.2 Mechanical Properties of Solid Polymers 2.1.3.3 Other Properties of Solid Polymers 2.1.3.4 Properties of Liquid Polymers 2.1.3.5 Healing of Polymers 2.1.3.6 Liquid Crystalline Polymers 2.1.3.7 Elastomers 2.1.4 Polymers as Composite Matrices 2.1.5 Thermoplastic Polymer Matrices 2.1.5.1 Polyethylenes 2.1.5.2 Polypropylenes 2.1.5.3 Polyamides 2.1.5.4 Thermoplastic Polyesters 2.1.5.5 Poly(phenylene Sulfides) 2.1.5.6 Polyketones 2.1.5.7 Polysulfones 2.1.5.8 Thermoplastic Polyimides 2.1.6 Thermoset Polymer Matrices 2.1.6.1 Unsaturated Polyesters 2.1.6.2 Epoxies 2.1.6.3 Vinylesters 2.1.6.4 Phenolics 2.1.6.5 Other Thermosets 2.1.7 Matrix Forms 2.1.8 Additives 2.2 Reinforcements 2.2.1 Glass Fibers 2.2.2 Carbon Fibers 2.2.3 Aramid Fibers 2.2.4 Polyethylene Fibers 2.2.5 Other Fibers 2.2.6 Reinforcement-Matrix Interaction 2.2.7 Fibrous Reinforcement Forms 2.2.7.1 Weaving 2.2.7.2 Noncrimp Fabrics 2.2.7.3 Knitting 2.2.7.4 Braiding 2.2.7.5 Mats and Non-Wovens 2.2.7.6 Combination Fabrics and Preforms 2.3 Preimpregnated Reinforcement 2.3.1 Solvent Impregnation 2.3.2 Melt Impregnation 2.3.3 Powder Impregnation 2.3.4 Commingling 2.3.5 Comparison of Preimpregnated Reinforcement Types 2.3.6 Molding Compounds 2.4 Core Materials 2.4.1 Wood Cores 2.4.2 Honeycomb and Corrugated Cores 2.4.3 Expanded Foam Cores 2.5 Adhesives 2.6 Composites Based on Inorganic Matrices 2.6.1 Carbon-Carbon Composites 2.6.2 Metal-Matrix Composites 2.6.3 Ceramic-Matrix Composites 2.7 Summary Suggested Further Reading References 3: PROPERTIES 3.1 Matrices 3.1.1 Thermal Properties 3.1.2 Mechanical Properties 3.2 Reinforcements 3.2.1 Thermal Properties 3.2.2 Mechanical Properties 3.3 Composites 3.3.1 Prediction of Thermal Properties 3.3.2 Prediction of Mechanical Properties 3.3.3 Comparisons of Predicted Mechanical Properties 3.3.4 Experimentally Determined Thermal Properties 3.3.5 Experimentally Determined Mechanical Properties 3.4 Core Materials 3.5 Sandwich Components 3.6 Summary Suggested Further Reading References 4: MANUFACTURING TECHNIQUES 4.1 Generic Manufacturing-related Issues 4.1.1 Mold Fabrication 4.1.1.1 Direct Manual Mold Fabrication 4.1.1.2 Mold Fabrication Using a Master Model 4.1.1.3 Mold Fabrication through Direct Machining 4.1.1.4 Flexible Molds 4.1.2 Reinforcement Conformability 4.1.3 Prepreg Conformability 4.1.4 Heat Transfer 4.2 Thermoset–Matrix Techniques 4.2.1 Wet Layup 4.2.1.1 Hand Layup 4.2.1.2 Spray-up 4.2.1.3 Hand Layup of Sandwich Components 4.2.2 Prepreg Layup 4.2.3 Liquid Molding 4.2.3.1 Injection Molding 4.2.3.2 Resin Transfer Molding 4.2.3.3 Vacuum Injection Molding 4.2.3.4 Reaction Injection Molding 4.2.3.5 Reinforced Reaction Injection Molding 4.2.3.6 Structural Reaction Injection Molding 4.2.4 Compression Molding 4.2.5 Filament Winding 4.2.6 Pultrusion 4.2.7 Other Techniques 4.3 Thermoplastic–Matrix Techniques 4.3.1 Prepreg Layup 4.3.2 Liquid Molding 4.3.3 Compression Molding 4.3.3.1 Compression Molding of GMT 4.3.3.2 Compression Molding of Prepregs and Flat Laminates 4.3.4 Filament Winding 4.3.5 Pultrusion 4.3.6 Diaphragm Forming 4.3.7 Other Techniques 4.4 Manufacturing-induced Component Defects 4.4.1 Structural Defects 4.4.1.1 Deviations in Reinforcement Orientation and Content 4.4.1.2 Voids 4.4.1.3 Incomplete Impregnation and Mold Filling 4.4.1.4 Variations in Constituent Properties 4.4.2 Geometrical Defects 4.4.3 Cosmetic Defects 4.5 Summary Suggested Further Reading References 5: SECONDARY PROCESSING 5.1 Machining 5.1.1 Conventional Cutting Techniques 5.1.1.1 Drilling 5.1.1.2 Sawing 5.1.1.3 Edge Trimming 5.1.1.4 Other Cutting Operations 5.1.2 Waterjet Machining 5.1.3 Laser Machining 5.1.4 Other Machining Techniques 5.2 Joining 5.2.1 Mechanical Joining 5.2.2 Adhesive Joining 5.2.3 Cocuring and Lamination 5.2.4 Fusion Bonding 5.2.5 Solvent Bonding 5.2.6 Joining of Sandwich Components 5.3 Surface Finishing 5.4 Repair 5.5 Summary Suggested Further Reading References 6: QUALITY CONTROL AND CHARACTERIZATION 6.1 Constituent Quality Control and Characterization 6.2 Composite Characterization 6.2.1 Physical Properties 6.2.1.1 Constituent Fractions through Matrix Burn-off 6.2.1.2 Constituent Fractions through Matrix Digestion 6.2.1.3 Constituent Fractions through Microscopy 6.2.1.4 Void Fraction and Density 6.2.2 Mechanical Properties 6.2.2.1 Tensile Properties 6.2.2.2 Compressive Properties 6.2.2.3 Shear Properties 6.2.2.4 Flexural Properties 6.2.3 Thermal Properties 6.3 Composite Quality Control 6.3.1 Destructive Testing 6.3.2 Nondestructive Testing 6.3.2.1 Visual Inspection 6.3.2.2 Ultrasonic Inspection 6.3.2.3 Vibrational Inspection 6.3.2.4 Radiographic Inspection 6.3.2.5 Thermographic Inspection 6.3.2.6 Acoustic Emission Inspection 6.3.2.7 Eddy-current Inspection 6.3.2.8 Optical Inspection 6.4 In-service Inspection 6.5 Summary Suggested Further Reading References 7: RECYCLING 7.1 Incentives 7.2 Infrastructure 7.3 Recycling Techniques 7.3.1 Primary and Secondary Recycling 7.3.1.1 Thermoset Composites 7.3.1.2 Thermoplastic Composites 7.3.2 Tertiary Recycling 7.3.3 Quaternary Recycling 7.4 Market Commitment 7.5 Green Thinking in Design 7.5.1 Design for Minimization of Waste 7.5.2 Design for Recycling 7.5.3 Component Labeling 7.6 Summary Suggested Further Reading References 8: HEALTH AND SAFETY 8.1 Terminology 8.2 Routes of Exposure and Harmful Effects 8.3 Protective Measures 8.3.1 Administrative Controls 8.3.2 Engineering Controls 8.3.3 Personal Protective Equipment 8.3.4 First Aid 8.4 Constituent Materials 8.4.1 Matrices, Adhesives, and Solvents 8.4.1.1 Thermoplastics 8.4.1.2 Unsaturated Polyesters and Vinylesters 8.4.1.3 Epoxies 8.4.1.4 Other Thermosets 8.4.1.5 Solvents 8.4.2 Reinforcements and Fillers 8.4.3 Preimpregnated Reinforcement 8.4.4 Core Materials 8.5 Manufacturing Techniques 8.5.1 Mold and Tool Cleaning 8.5.2 Resin Formulation 8.5.3 Wet Layup 8.5.4 Prepreg Layup 8.5.5 Liquid Molding 8.5.6 Compression Molding 8.5.7 Filament Winding 8.5.8 Pultrusion 8.5.9 Thermoplastic–Matrix Techniques 8.6 Machining 8.7 Summary Disclaimer Suggested Further Reading References Index