FIBRE REINFORCED

COMPOSITES

Z.SHANTI KIRAN
SURESH.J

NAGENDRA PRASAD

JAISON JACOB

CONTENT
1.RESINS(POLYMERS).
2.FIBERS.
3.MANUFACTURING PROCESSES.
4.APPLICATIONS.

POLYMERS
WIDE VARIETY AVAILABLE
SELECTION BASED ON:
PHYSICAL AND MECHANICAL PROPERTIES OF

PRODUCT
FABRICATION PROCESS REQUIREMENTS

TYPES OF RESINS
THERMOSET
THERMOPLASTIC

THERMOSET
POLYESTER
VINYL ESTER
EPOXY
PHENOLIC
POLYURETHANE

THERMOPLASTIC
ACETAL
ACRYRONITRILE BUTADIENE STYRENE (ABS)
NYLON
POLYETHYLENE (PE)
POLYPROPYLENE (PP)
POLYETHYLENE TEREPHTHALATE (PET)

THERMOSET ADVANTAGES
THERMAL STABILITY
CHEMICAL RESISTANCE
REDUCED CREEP AND STRESS RELAXATION
LOW VISCOSITY- EXCELLENT FOR FIBER

ORIENTATION

THERMOPLASTIC ADVANTAGES
ROOM TEMPERATURE MATERIAL STORAGE
RAPID, LOW COST FORMING
REFORMABLE

POLYESTERS
LOW COST
EXTREME PROCESSING VERSATILITY
MAJOR USES:
Transportation

Construction
Marine

VINYL ESTER
SIMILAR TO POLYESTER
EXCELLENT MECHANICAL & FATIGUE PROPERTIES
EXCELLENT CHEMICAL RESISTANCE
MAJOR USES:
Corrosion

Applications - Pipes, Tanks, & Ducts

EPOXY
EXCELLENT MECHANICAL PROPERTIES
GOOD FATIGUE RESISTANCE
LOW SHRINKAGE
GOOD HEAT AND CHEMICAL RESISTANCE
MAJOR USES:
FRP

Strengthening Systems
FRP Rebars
FRP Stay-in-Place Forms

PHENOLICS
EXCELLENT FIRE RETARDANCE
LOW SMOKE & TOXICITY EMISSIONS
HIGH STRENGTH AT HIGH TEMPERATURES
MAJOR USES:
Mass

Transit - Fire Resistance & High Temperature

Ducting

POLYURETHANE
TOUGH
GOOD IMPACT RESISTANCE
GOOD SURFACE QUALITY
MAJOR USES:
Bumper

Beams, Automotive Panels

Physical Properties of
Thermosetting Resins Used in
Structural Composites

MAN-MADE FIBERS
ARAMID
BORON
CARBON/GRAPHITE
GLASS
NYLON
POLYESTER
POLYETHYLENE
POLYPROPYLENE

FIBERS
Generally circular in cross-section, but can also be in the form

of tubular, rectangle, hexagonal.

Fibers used can be either continuous or discontinuous
Continuous fibers : are very long; in theory, they offer a
continuous path by which a load can be carried by composite
material.
Discontinuous fibers : are short lengths.

FIBER PROPERTIES
DENSITY (g/cm3)

FIBER PROPERTIES
TENSILE STRENGTH

FIBER PROPERTIES
STRAIN TO FAILURE

FIBER
REINFORCEMENT
GLASS
MOST COMMON FIBER USED
HIGH STRENGTH
GOOD WATER RESISTANCE
GOOD ELECTRIC INSULATING PROPERTIES
LOW STIFFNESS

GLASS TYPES
E-GLASS
S-GLASS
C-GLASS
ECR-GLASS
AR-GLASS

FIBER
REINFORCEMENT
ARAMID (KEVLAR)
SUPERIOR RESISTANCE TO DAMAGE (ENERGY

ABSORBER)
GOOD IN TENSION APPLICATIONS (CABLES,
TENDONS)
MODERATE STIFFNESS
MORE EXPENSIVE THAN GLASS

CARBON
GOOD MODULUS AT HIGH TEMPERATURES
EXCELLENT STIFFNESS
MORE EXPENSIVE THAN GLASS
BRITTLE
LOW ELECTRIC INSULATING PROPERTIES

ADVANTAGES AND
DISADVANTAGES OF
REINFORCING FIBERS

Fiber Terminology

FILLERS
To improve performance
Reduce the cost of a composite.
Reduce mould Shrinkage.
Surface smoothness.
Crack resistance.
Enhance compressive strength.

Different fillers used:

Marble dust.
Silicon dioxide.
Alumino-silicate sand.
Calcium Carbonate
Kaolin
Alumina Trihydrate
Mica Feldspar
Wollastonite

ADDITIVES
A constituent component that may be added to the composite

matrix to modify its properties and in general, enhance its

performance.
Additives include catalysts, colorants, flame retardants and
other ingredients that expand and improve the capabilities of
the matrix.
Additives like antimony trioxide and alumina trihydrate,
improve the fire retardancy of frp.

FEATURES OF FRP:
High strength-to-weight ratio.
High modulus-to-weight ratio.
Low specific gravity.
Good fatigue strength.
Good corrosion resistance, although polymers are soluble in

various chemicals.
Low thermal expansion, leading to good dimensional stability.
Significant in anisotropy properties.

MANUFACTURING PROCESSES
OF FRP
Hand Lay-up/Spray-up
Resin Transfer Molding (RTM)
Compression Molding
Injection Molding
Reinforced Reaction Injection Molding (RRIM)
Pultrusion
Filament Winding
Vacuum Assisted RTM (Va-RTM)
Centrifugal Casting

Manufacturing Processes
1. Hand Lay-up Process:
Matrixes/Resins are impregnated by hand into fibers
which are in the form of chopped strand mat woven or
bonded fabrics. This is usually accomplished by rollers or
brushes, with an increasing use of nip-roller type
impregnators for forcing resin into the fabrics by means of
rotating rollers and a bath of resin.
Laminates are left to cure under standard atmospheric
conditions.

ADVANTAGES
Corrosion Resistant
Low maintenance requirement
Impact resistance
Non-conductive and Non metallic
Fire Retardant
High strength-to-weight ratio
Reduced installation time and cost

DISADVANTAGES
High Cost.
Creep and Shrinkage.
Potential for Environmental Degradation (Alkalis' Attack,

UV Radiation Exposure, Moisture Absorption, etc).

Global and Local Buckling
Aerodynamic Instability With Lightweight
Requires Highly Trained Specialists
Limited Joining and Connection Technology (Adhesive
joints, fasteners)

2.Spray Lay up
Fiber is chopped in a hand-held gun and fed into a spray of

catalyzed resin directed at the mould. The deposited materials

are left to cure under standard atmospheric conditions.
Materials Options:
Resins: Primarily polyester.
Fibers: Glass roving only.
Cores: None. These have to be incorporated separately.

Advantages:
i) Large and complex items can be produced.
ii) Design flexibility.
iii) Low cost tooling.
Disadvantages:
i) Low volume process.
ii)Quality is related to the skill of operator.
iii) Product uniformity is difficult.
Typical Applications:
Simple enclosures, lightly loaded structural panel for
caravan bodies, truck fairings, bathtubs, shower
trays.

APPLICATIONS
Simple enclosures,
lightly loaded structural panel for caravan
bodies,
truck fairings,
bathtubs,
shower trays.

3.Filament Winding
This process is primarily used for hollow, generally circular or

oval sectioned components, such as pipes and tanks.

Fiber tows are passed through a resin bath before being wound
onto a mandrel in a variety of orientations, controlled by the
fiber feeding mechanism, and rate of rotation of the mandrel.
Materials Options: Resins: i.e. epoxy, polyester, vinyl ester
and phenolic.
Fibers: The fibers are used straight from a creel and not
woven or stitched into a fabric form.
Cores: Any, although components are usually single skin.

ADVANTAGES:
This can be a very fast and therefore economic

method of laying material down.

Versatility is obtained.
Fiber cost is minimized since there is no secondary
process to convert fiber into fabric prior to use.
Structural properties of laminates can be very good
since straight fibers can be laid in a complex pattern to
match the applied loads.

DISADVANTAGES:
The process is limited to convex shaped components.
There is poor external surface.
Mandrel costs for large components can be high.
Winding at low angles is difficult .

APPLICATIONS OF FRP
New Bridge Structures
Enclosures
Bonded Steel Plates
Bonded Carbon Laminates
Cables
Rope
Rods
Anchors
Research
Manufacturing

STORCHENBRUCKE (Stork Bridge) Switzerland

First Cable-Stayed Road Bridge; 406 ft
Length with Pylon Height of 125 ft
Construction in 1994-96; 2 of 24 CFRP
Cable Stays

SECOND SEVERN ENCLOSEURE

SYSTEM - UK
Construction 1993
Bridge Bottom Soffit Enclosure
System
40 psf Design Load With L/120
Deflection

FRP INDUSTRIES IN INDIA.

THANKYOU