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Composite materials with textile reinforcements

Defined broadly, a composite material is a combination of different materials, which has features that are not part of the constituent materials. In many cases, materials, natural or synthetic, are found in combination with other materials and not acting alone. If the human body is built of flesh and bone of reinforced concrete where cement is poured onto a metal frame. Synthetic composites have first appeared in the aerospace industry, the need to control and improve properties of materials in accordance with the requirements of the destination. There are several variants of the definition of composite materials. The most comprehensive, best characterize their nature is given by P. Mallick. According to Mallick, "A composite is a combination of two or more different materials in chemical terms, with an interface between them. Constituent materials retain their separate identity (at least at the macroscopic level) in the composite, however, their combination generates all the different properties and characteristics of the material component. One is called the matrix material and is defined as forming the continuous phase. The other main element is called a reinforcement (textiles) and add the matrix to improve or modify its properties. Discontinuous reinforcement phase is distributed uniformly in the entire volume of the matrix. " Constituent elements of the composite materials have predetermined roles and behaviors, as shown in figure 1.

Figure 1. Characteristic behavior of composite materials constituent elements and assembly

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Fiber is the element which gives all the characteristics of resistance to requests. Compared with the matrix, which can be downloaded effort is superior, while adequate elongation is reduced. The matrix has a tensile elongation and a much larger toughness, which ensures that the fibers break before the matrix to yield. Specific curves illustrated characterize individual behavior reinforcement and matrix, but it should be noted that the composite material is a complex whole in which the two phases work together, as suggested load extension curve for the composite. Liaison element matrix is the material, that: maintain the unity of the ensemble, acting as a medium for the transmission of tension in the reinforcing structure and the latter protects the destructive action of external factors. Depending on the nature of the matrix, the composites can be grouped into four broad categories:
i polymer matrix composite materials - are the most common composite is known as

polymer (plastic) with textile reinforcement;

i metal matrix composite materials - use materials such as aluminum metal matrix and

reinforcement such as textile fibers such as silicon. They are used in the automotive industry;
i ceramic matrix composite materials - find applicability in situations characterized by high

temperatures, the short fiber reinforcement is used or particles of boron carbide or nitrate;
i cement matrix composite materials - are specific to the construction industry, all offering

special properties of strength, drainage, etc..

Processes to obtain composite materials

As a general principle, the composites are produced by introducing the matrix (resin) in the reinforcement system, followed by its polymerization reaction, called cleaning, a reaction that forms the link between the two components. Cleaning depends on the type of resin used - thermoset or thermoplastic, conditions affecting the process, including time, temperature and pressure. To get the default form of the piece, reinforcing materials are placed in molds. Depending on the type of mold can highlight two types of production processes for composite materials: open mold processes - only one side of the reinforcing material in contact with molds. closed mold processes - reinforcement material in contact with the mold on both sides.

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There are a wide variety of processes, from manual to fully automated, from processes to processes that require cold temperature and pressure conditions. The following will briefly present the main processes of the two groups.

Processes for producing composite materials with open dies

Open mold technique involves using a single mold, reinforcing material can be disposed inside or outside the mold. This group includes: stamping by contact (manual submission), stamping, spray, vacuum stamping with reinforcement in the film, stamping and winding autoclave. These processes are based on the characteristics of thermoset resins, especially those polyester can polymerize without the temperature and pressure

1. Drop by contact (manual submission)

Drop by manually submitting reinforcement is the simplest and oldest method of producing composite materials. You can use any type of thermoset resin such as epoxy, polyester, vinyl ester or phenolic. Used as reinforcing fibers extend the full range of high strength fibers and how in general the 2D materials - fabrics, knitted fabrics, braiding, fiber blankets. The basic principle of the technological process is illustrated in Figure 2. Reinforcing material is deposited on the resin matrix and extends its surface with a roller. Depending on the resin used, cleaning can be done at ambient temperature or in oven at 800 C. The duration of the process varies from 8-10 hours to 3 to 7 days.

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To prevent adhesion problems may occur when removing the material, the mold is advisable to apply a protective layer with a uniform thickness of about 0.35 mm. Most commonly used are: gels, waxes, silicones, carbon fluoride compounds, etc. The main advantages of matri rii with manual submission are: technique is simple and extremely widespread; equipment is cheap, especially if cold cleaning; can use any type of fiber reinforcement and resin system; composite materials thus obtained are characterized by a high volume fraction of the spray for stamping. In return, the disadvantages include:
ifinal quality of the composite material depends largely on the experience of the operator; i direct manipulation of the resin raises issues of safety rules; i volatile substances exceed the limit imposed by the rules; ilow viscosity imposed a negative influence due to manual handling, mechanical and thermal

properties of composite material.

2. Drop by spraying

In the case of complex shapes, stamping with manual submission is much too laborious and time consuming. Drop by spraying has emerged as an alternative in which both the reinforcing short fibers and resin are sprayed on the mold using special spray. The fibers are taken up in the cable, cut to desired length and then mixed with the resin in the air. There are three ways to accomplish this mix: outdoor mix - fiber and resin are sprayed separately, as shown in Figure 3; mix inside - the resin and fibers are first mixed in a spray chamber and the mixture is sprayed onto the mold; pressure vessels - is a variant of the mixture on the outside, the separate flows of resin and fiber are produced by the pressure in the vessels.

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Between applications of composite materials produced with this technique include: parts for showers, small ornamental columns, steps for swimming pools, etc.. Composite material quality depends largely on the volume fraction value. The proportion of fiber / resin is controlled by setting precise amount of polymer required additional substances and by monitoring the consumption of fiber and resin, so that produces a uniform deposit. And if spray low viscosity of the matrix affects the mechanical and thermal properties. Mechanical properties are influenced by the fact that fiber reinforcement is provided only short. However, there is a risk that the presence of volatile substances, styrene type, exceed the prescribed standards.

3. Fiber winding
Filament winding is a manufacturing process of composite materials which type continuous reinforcement materials (filaments, yarns, tapes, etc.), impregnated with resin before or during the process, are deposited on a rotatable form, so that they fulfill certain conditions related to tension in the winding. In general, the surface shape is tubular, closed or open. After winding the desired number of layers, there is clean and remove all supported format. If the winding is made with the introduction of matrix reinforcement system in an earlier

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phase (using so-called "prepregs"), then the process is dry type. The process is characterized by passing the wet reinforcement through a resin bath. Winding can be done on the circumference of support form or shape including heads, socalled polar winding. Circumference of the winding form is obtained by using a mobile carriage carrying filaments along the surface. The correlation between the shape and movement of the trolley winding determines the type - a cross or parallel, and the angle of winding. To improve the mechanical properties, can be inserted in the longitudinal direction and filaments, yarns, tapes. In winding polar filaments are made from one end to another, thereby creating a closed form. The trolley, which are mounted bath of resin and wire rack, is a race around the base elliptical. The shape is slightly inclined to the horizontal axis of the ellipse. For example, in Figure 4 is a schematic drawing of the technological process for winding filaments cross type, where a wet process.

Removing support form after the cleaning process can be its removal by solvers (water or alkaline agents, depending on the raw material form) or simply be left in the composite material. Produced by filament winding of composite materials used in aviation and aerospace industry for components such as rocket engines, fuselages, propellers, helicopters, tanks and pressure vessels, pipes, etc.. Winding has the advantage of high productivity, which eliminates the initial stage of

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implementation of reinforcement material. Composites thus obtained are characterized by excellent mechanical properties of filaments in the direction of deposition, and a high content of fiber (by volume). However, the use of low viscosity resins limited mechanical behavior. Other disadvantages are related forms of support costs, nefinisarea limitations of these forms and the exterior of the composite material.