Polymer matrix composite

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In materials science, a polymer matrix composite (PMC) is a composite material composed of a variety of short or continuous fibers bound together by a matrix of organic polymers. PMCs are designed to transfer loads between fibers of a matrix. Some of the advantages with PMCs include their light weight, high resistance to abrasion and corrosion, and high stiffness and strength along the direction of their reinforcements. [1]

Contents

Matrix materials

The function of the matrix in PMCs is to bond the fibers together and transfer loads between them. [2] PMCs matrices are typically either thermosets or thermoplastics. Thermosets are by far the predominant type in use today. Thermosets are subdivided into several resin systems including epoxies, phenolics, polyurethanes, and polyimides. Of these, epoxy systems currently dominate the advanced composite industry. [3] [4] [5]

Thermosets

Thermoset resins require addition of a curing agent or hardener and impregnation onto a reinforcing material, followed by a curing step to produce a cured or finished part. Once cured, the part cannot be changed or reformed, except for finishing. Some of the more common thermosets include epoxy, polyurethanes, phenolic and amino resins, bismaleimides (BMI, polyimides), polyamides. [3] [4] [5]

Of these, epoxies are the most commonly used in the industry. Epoxy resins have been in use in U.S. industry for over 40 years. Epoxy compounds are also referred to as glycidyl compounds. The epoxy molecule can also be expanded or cross-linked with other molecules to form a wide variety of resin products, each with distinct performance characteristics. These resins range from low-viscosity liquids to high-molecular weight solids. Typically they are high-viscosity liquids.

The second of the essential ingredients of an advanced composite system is the curing agent or hardener. These compounds are very important because they control the reaction rate and determine the performance characteristics of the finished part. Since these compounds act as catalysts for the reaction, they must contain active sites on their molecules. Some of the most commonly used curing agents in the advanced composite industry are the aromatic amines. Two of the most common are methylene-dianiline (MDA) and sulfonyldianiline (DDS).[ citation needed ] SiC–SiC matrix composites are a high-temperature ceramic matrix processed from preceramic polymers (polymeric SiC precursors) to infiltrate a fibrous preform to create a SiC matrix. [6]

Several other types of curing agents are also used in the advanced composite industry. These include aliphatic and cycloaliphatic amines, polyaminoamides, amides, and anhydrides. Again, the choice of curing agent depends on the cure and performance characteristics desired for the finished part. Polyurethanes are another group of resins used in advanced composite processes. These compounds are formed by reacting the polyol component with an isocyanate compound, typically toluene diisocyanate (TDI); methylene diisocyanate (MDI) and hexamethylene diisocyanate (HDI) are also widely used. Phenolic and amino resins are another group of PMC resins. The bismaleimides and polyamides are relative newcomers to the advanced composite industry and have not been studied to the extent of the other resins. [3] [4] [5]

Thermoplastics

Thermoplastics currently represent a relatively small part of the PMC industry. They are typically supplied as nonreactive solids (no chemical reaction occurs during processing) and require only heat and pressure to form the finished part. Unlike the thermosets, the thermoplastics can usually be reheated and reformed into another shape, if desired. [3] [4] [5]

Dispersed materials

Fibers

Fiber-reinforced PMCs contain about 60 percent reinforcing fiber by volume. The fibers that are commonly found and used within PMCs include fiberglass, graphite and aramid. Fiberglass has a relatively low stiffness at the same time exhibits a competitive tensile strength compared to other fibers. The cost of fiberglass is also dramatically lower than the other fibers which is why fiberglass is one of the most widely used fiber. [1] The reinforcing fibers have their highest mechanical properties along their lengths rather than their widths. Thus, the reinforcing fibers maybe arranged and oriented in different forms and directions to provide different physical properties and advantages based on the application. [7] [8]

Carbon Nanotubes

Unlike fiber-reinforced PMCs, nanomaterials reinforced PMCs are able to achieve significant improvements in mechanical properties at much lower (less than 2% by volume) loadings. [9] Carbon nanotubes in particular have been intensely studied due to their exceptional intrinsic mechanical properties and low densities. In particular carbon nanotubes have some of the highest measured tensile stiffnesses and strengths of any material due to the strong covalent sp2 bonds between carbon atoms. However, in order to take advantage of the exceptional mechanical properties of the nanotubes, the load transfer between the nanotubes and matrix must be very large.

Like in fiber-reinforced composites, the size dispersion of the carbon nanotubes significantly affects the final properties of the composite. Stress-strain studies of single-walled carbon nanotubes in a polyethylene matrix using molecular dynamics showed that long carbon nanotubes lead to an increase in tensile stiffness and strength due to the large-distance stress transfer and crack propagation prevention. On the other hand short carbon nanotubes do not lead to any enhancement of properties without any interfacial adhesion. [10] However once modified, short carbon nanotubes are able to further improve the stiffness of the composite, however there is still very little crack propagation countering. [11] In general, long and high aspect ratio carbon nanotubes lead to greater enhancement of mechanical properties, but are more difficult to process.

Aside from size, the interface between the carbon nanotubes and the polymer matrix is of exceptional importance. In order to achieve better load transfer, a number of different methods have been used to better bond the carbon nanotubes to the matrix by functionalizing the surface of the carbon nanotube with various polymers. These methods can be divided into non-covalent and covalent strategies. Non-covalent CNT modification involves the adsorption or wrapping of polymers to the carbon nanotube surface, usually via van der Waals or π-stacking interactions. In contrast, covalent functionalization involves direct bonding onto the carbon nanotube. This can be achieved in a number of ways, such as oxidizing the surface of the carbon nanotube and reacting with the oxygenated site, or using a free radical to directly react with the carbon nanotube lattice. [12] Covalent functionalization can be used to directly attach the polymer to the carbon nanotube, or to add an initiator molecule which can then be used for further reactions.

The synthesis of carbon nanotube reinforced PMCs is dependent on the choice of matrix and functionalization of the carbon nanotubes. [13] For thermoset polymers, solution processing is used where the polymer and nanotubes are placed in an organic solvent. The mixture is then sonicated and mixed until the nanotubes are evenly dispersed, then cast. While this method is widely used, the sonication can damage the carbon nanotubes, the polymer must be soluble in the solvent of choice, and the rate of evaporation can often lead to undesirable structures like nanotube bundling or polymer voids. For thermoplastic polymers, melt-processing can be used, where the nanotube is mixed into the melted polymer, then cooled. However, this method cannot tolerate high carbon nanotube loading due to viscosity increases. In-situ polymerization can be used for polymers that are not solvent or heat compatible. In this method, the nanotubes are mixed with the monomer, which is then reacted to form the polymer matrix. This method can lead to especially good load transfer if monomers are also attached to the carbon nanotube surface.

Graphene

Like carbon nanotubes, pristine graphene also possesses exceptionally good mechanical properties. Graphene PMCs are typically processed in the same manner as carbon nanotube PMCs, using either solution processing, melt-processing, or in-situ polymerization. While the mechanical properties of graphene PMCs are typically worse than their carbon nanotube equivalents, graphene oxide is much easier to functionalize due to the inherent defects present. Additionally, 3D graphene polymer composites show some promise for the isotropic enhancement of mechanical properties. [14]

Related Research Articles

<span class="mw-page-title-main">Composite material</span> Material made from a combination of two or more unlike substances

A composite material is a material which is produced from two or more constituent materials. These constituent materials have notably dissimilar chemical or physical properties and are merged to create a material with properties unlike the individual elements. Within the finished structure, the individual elements remain separate and distinct, distinguishing composites from mixtures and solid solutions. Composite materials with more than one distinct layer are called composite laminates.

Fiberglass or fibreglass is a common type of fiber-reinforced plastic using glass fiber. The fibers may be randomly arranged, flattened into a sheet called a chopped strand mat, or woven into glass cloth. The plastic matrix may be a thermoset polymer matrix—most often based on thermosetting polymers such as epoxy, polyester resin, or vinyl ester resin—or a thermoplastic.

<span class="mw-page-title-main">Epoxy</span> Type of material

Epoxy is the family of basic components or cured end products of epoxy resins. Epoxy resins, also known as polyepoxides, are a class of reactive prepolymers and polymers which contain epoxide groups. The epoxide functional group is also collectively called epoxy. The IUPAC name for an epoxide group is an oxirane.

<span class="mw-page-title-main">Thermosetting polymer</span> Polymer obtained by irreversibly hardening (curing) a resin

In materials science, a thermosetting polymer, often called a thermoset, is a polymer that is obtained by irreversibly hardening ("curing") a soft solid or viscous liquid prepolymer (resin). Curing is induced by heat or suitable radiation and may be promoted by high pressure or mixing with a catalyst. Heat is not necessarily applied externally, and is often generated by the reaction of the resin with a curing agent. Curing results in chemical reactions that create extensive cross-linking between polymer chains to produce an infusible and insoluble polymer network.

Pre-preg is a composite material made from "pre-impregnated" fibers and a partially cured polymer matrix, such as epoxy or phenolic resin, or even thermoplastic mixed with liquid rubbers or resins. The fibers often take the form of a weave and the matrix is used to bond them together and to other components during manufacture. The thermoset matrix is only partially cured to allow easy handling; this B-Stage material requires cold storage to prevent complete curing. B-Stage pre-preg is always stored in cooled areas since heat accelerates complete polymerization. Hence, composite structures built of pre-pregs will mostly require an oven or autoclave to cure. The main idea behind a pre-preg material is the use of anisotropic mechanical properties along the fibers, while the polymer matrix provides filling properties, keeping the fibers in a single system.

Gelcoat or gel coat is a material used to provide a high-quality finish on the visible surface of a fibre-reinforced composite. The most common gelcoats are thermosetting polymers based on epoxy or unsaturated polyester resin chemistry. Gelcoats are modified resins which are applied to moulds in the liquid state. They are cured to form crosslinked polymers and are subsequently backed with thermoset polymer matrix composites which are often mixtures of polyester resin and fiberglass, or epoxy resin which is most commonly used with carbon fibre for higher specific strength.

A non-carbon nanotube is a cylindrical molecule often composed of metal oxides, or group III-Nitrides and morphologically similar to a carbon nanotube. Non-carbon nanotubes have been observed to occur naturally in some mineral deposits.

<span class="mw-page-title-main">Nanocomposite</span> Solid material with nano-scale structure

Nanocomposite is a multiphase solid material where one of the phases has one, two or three dimensions of less than 100 nanometers (nm) or structures having nano-scale repeat distances between the different phases that make up the material.

Bulk moulding compound (BMC), bulk moulding composite, or dough moulding compound (DMC), is a ready-to-mold, glass-fiber reinforced thermoset polymer material primarily used in compression moulding, as well as in injection moulding and transfer moulding. Typical applications include demanding electrical applications, corrosion resistant needs, appliance, automotive, and transit.

Sheet moulding compound (SMC) or sheet moulding composite is a ready to mould glass-fibre reinforced polyester material primarily used in compression moulding. The sheet is provided in rolls weighing up to 1000 kg. Alternatively the resin and related materials may be mixed on site when a producer wants greater control over the chemistry and filler.

Polymer engineering is generally an engineering field that designs, analyses, and modifies polymer materials. Polymer engineering covers aspects of the petrochemical industry, polymerization, structure and characterization of polymers, properties of polymers, compounding and processing of polymers and description of major polymers, structure property relations and applications.

Exfoliated graphite nano-platelets (xGnP) are new types of nanoparticles made from graphite. These nanoparticles consist of small stacks of graphene that are 1 to 15 nanometers thick, with diameters ranging from sub-micrometre to 100 micrometres. The X-ray diffractogram of this material would resemble that of graphite, in that the 002 peak would still appear at ~26o 2 theta. However, the peak would appear considerably smaller and broader. These features indicate that the interplanar distance in exfoliated graphite is similar to that of the parent graphite, but the stack size is small. Since xGnP is composed of the same material as carbon nanotubes, it shares many of the electrochemical characteristics, although not the tensile strength. The platelet shape, however, offers xGnP edges that are easier to modify chemically for enhanced dispersion in polymers.

A thermoset polymer matrix is a synthetic polymer reinforcement where polymers act as binder or matrix to secure in place incorporated particulates, fibres or other reinforcements. They were first developed for structural applications, such as glass-reinforced plastic radar domes on aircraft and graphite-epoxy payload bay doors on the Space Shuttle.

Carbon fiber-reinforced polymers, carbon-fibre-reinforced polymers, carbon-fiber-reinforced plastics, carbon-fiber reinforced-thermoplastic, also known as carbon fiber, carbon composite, or just carbon, are extremely strong and light fiber-reinforced plastics that contain carbon fibers. CFRPs can be expensive to produce, but are commonly used wherever high strength-to-weight ratio and stiffness (rigidity) are required, such as aerospace, superstructures of ships, automotive, civil engineering, sports equipment, and an increasing number of consumer and technical applications.

Vitrimers are a class of plastics, which are derived from thermosetting polymers (thermosets) and are very similar to them. Vitrimers consist of molecular, covalent networks, which can change their topology by thermally activated bond-exchange reactions. At high temperatures, they can flow like viscoelastic liquids; at low temperatures, the bond-exchange reactions are immeasurably slow (frozen), and the Vitrimers behave like classical thermosets at this point. Vitrimers are strong glass formers. Their behavior opens new possibilities in the application of thermosets, such as a self-healing material or simple processibility in a wide temperature range.

Glass-filled polymer, is a mouldable composite material. It comprises short glass fibers in a matrix of a polymer material. It is used to manufacture a wide range of structural components by injection or compression moulding. It is an ideal glass alternative that offers flexibility in the part, chemical resistance, shatter resistance and overall better durability.

A void or a pore is three-dimensional region that remains unfilled with polymer and fibers in a composite material. Voids are typically the result of poor manufacturing of the material and are generally deemed undesirable. Voids can affect the mechanical properties and lifespan of the composite. They degrade mainly the matrix-dominated properties such as interlaminar shear strength, longitudinal compressive strength, and transverse tensile strength. Voids can act as crack initiation sites as well as allow moisture to penetrate the composite and contribute to the anisotropy of the composite. For aerospace applications, a void content of approximately 1% is still acceptable, while for less sensitive applications, the allowance limit is 3-5%. Although a small increase in void content may not seem to cause significant issues, a 1-3% increase in void content of carbon fiber reinforced composite can reduce the mechanical properties by up to 20%

Thermoplastics containing short fiber reinforcements were first introduced commercially in the 1960s. The most common type of fibers used in short fiber thermoplastics are glass fiber and carbon fiber . Adding short fibers to thermoplastic resins improves the composite performance for lightweight applications. In addition, short fiber thermoplastic composites are easier and cheaper to produce than continuous fiber reinforced composites. This compromise between cost and performance allows short fiber reinforced thermoplastics to be used in myriad applications.

Transfer molding is a manufacturing process in which casting material is forced into a mold. Transfer molding is different from compression molding in that the mold is enclosed rather than open to the fill plunger resulting in higher dimensional tolerances and less environmental impact. Compared to injection molding, transfer molding uses higher pressures to uniformly fill the mold cavity. This allows thicker reinforcing fiber matrices to be more completely saturated by resin. Furthermore, unlike injection molding, the transfer mold casting material may start the process as a solid. This can reduce equipment costs and time dependency. The transfer process may have a slower fill rate than an equivalent injection molding process.

Covalent adaptable networks (CANs) are a type of polymer material that closely resemble thermosetting polymers (thermosets). However, they are distinguished from thermosets by the incorporation of dynamic covalent chemistry into the polymer network. When a stimulus (for example heat, light, pH, ...) is applied to the material, these dynamic bonds become active and can be broken or exchanged with other pending functional groups, allowing the polymer network to change its topology. This introduces reshaping, (re)processing and recycling into thermoset-like materials.

References

  1. 1 2 "Advanced Materials by Design (Part 6 of 18)" (PDF). Princeton.edu. Retrieved 2017-04-18.
  2. ↑ "Advanced Materials by Design (Part 6 of 18)" (PDF). Princeton.edu. Retrieved 2017-04-18.
  3. 1 2 3 4 Pilato, L.; Michno, Michael J. (January 1994). Advanced composite materials (Chap 1 Introduction, and Chapter 2 "Matrix Resins"). Springer-Verlag New York. ISBN   978-3-540-57563-4.
  4. 1 2 3 4 OSHA (May 4, 2009). "Polymer Matrix Materials: Advanced Composites". U.S. Department of Labor. Archived from the original on 28 May 2010. Retrieved 2010-06-05.PD-icon.svg This article incorporates text from this source, which is in the public domain .
  5. 1 2 3 4 ACG (2006). "Introduction to Advanced Composites and Prepreg Technology" (free PDF download). Advanced Composites Group. Retrieved 2010-06-05.
  6. ↑ Nannetti, C. A.; Ortona, A.; de Pinto, D. A.; Riccardi, B. (2004). "Manufacturing SiC-Fiber-Reinforced SiC Matrix Composites by Improved CVI/Slurry Infiltration/Polymer Impregnation and Pyrolysis". Journal of the American Ceramic Society. 87 (7): 1205–1209. doi:10.1111/j.1551-2916.2004.tb20093.x.
  7. ↑ "Polymer Matrix Composites (introduction)". SubsTech.com. 2006-11-06. Retrieved 2017-04-18.
  8. ↑ "Composite materials guide: Introduction – Polymer Composites | NetComposites Now". Netcomposites.com. 2017-03-31. Retrieved 2017-04-18.
  9. ↑ Spitalsky, Zdenko; Tasis, Dimitrios; Papagelis, Konstantinos; Galiotis, Costas (2010-03-01). "Carbon nanotube–polymer composites: Chemistry, processing, mechanical and electrical properties". Progress in Polymer Science. 35 (3): 357–401. doi:10.1016/j.progpolymsci.2009.09.003. ISSN   0079-6700.
  10. ↑ Frankland, S (August 2003). "The stress–strain behavior of polymer–nanotube composites from molecular dynamics simulation". Composites Science and Technology. 63 (11): 1655–1661. doi:10.1016/s0266-3538(03)00059-9. ISSN   0266-3538.
  11. ↑ Kar, Kamal K, éditeur intellectuel de compilation. Pandey, Jitendra K, éditeur intellectuel de compilation. Rana, Sravendra, éditeur intellectuel de compilation. (December 2014). Handbook of Polymer Nanocomposites. Processing, Performance and Application : Volume B: Carbon Nanotube Based Polymer Composites. ISBN   978-3-642-45229-1. OCLC   900797717.{{cite book}}: CS1 maint: multiple names: authors list (link)
  12. ↑ Koning, Cor. (2012). Polymer Carbon Nanotube Composites : the Polymer Latex Concept. CRC Press. ISBN   978-981-4364-16-4. OCLC   787843406.
  13. ↑ Andrews, R; Weisenberger, M. C (2004-01-01). "Carbon nanotube polymer composites". Current Opinion in Solid State and Materials Science. 8 (1): 31–37. Bibcode:2004COSSM...8...31A. doi:10.1016/j.cossms.2003.10.006. ISSN   1359-0286.
  14. ↑ Sreenivasulu, B; Ramji, BR.; Nagaral, Madeva (2018-01-01). "A Review on Graphene Reinforced Polymer Matrix Composites". Materials Today: Proceedings. International Conference on Advanced Materials and Applications (ICAMA 2016), June 15–17, 2016, Bengaluru, Karanataka, INDIA. 5 (1, Part 3): 2419–2428. doi:10.1016/j.matpr.2017.11.021. ISSN   2214-7853.
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