Students will be able to: Describe the types of fillers and fibers. Explain the similarities and differences between fillers and reinforcements. Discuss the current developments in fillers and fibres technology.
Students will be able to: Describe the types of fillers and fibers. Explain the similarities and differences between fillers and reinforcements. Discuss the current developments in fillers and fibres technology.
Students will be able to: Describe the types of fillers and fibers. Explain the similarities and differences between fillers and reinforcements. Discuss the current developments in fillers and fibres technology.
Polymer, UniKL 1 Chapter 2 UniKL MICET Fillers and Fibers JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS 2 Topic Outcomes It is expected that students will be able to: Describe the types of fillers and fibers. Explain the similarities and differences between fillers and fibers. Explain the theory of the action of fillers and reinforcements. Discuss the current developments in fillers and fibers technology. JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS 3 What are the definitions of fillers, and fibers?
What are the functions of fillers and fibers?
What are the differences between fillers and fibers? JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS 4 What are the differences between extender filler and reinforcing filler?
How they act as functional fillers to improve the mechanical properties?
What are the types of fillers and fibers? JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS ..as solid additives incorporated (fill space) into plastic matrix alter, increase or improve bulk properties 2 categories: inert or extender filler (cost reduction) Reinforcing fillers (mechanical properties) 5 JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS ..mainly, cost reduction volume/ density increase reduce plastics ..affect other properties, as well eg: talc (a fine-grained white, greenish, or gray mineral, Mg 3 Si 4 O 10 (OH) 2 ) ~ density h, shrinkage i, hardness h, heat deflection temp. h
6 Inert or extender fillers JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS ..improve the properties via several mechanisms. eg: a chemical bond is formed between the filler and the polymer eg: the volume occupied by the filler affects the properties of the thermoplastics ..due to the surface properties and interaction between the filler and the matrix (i.e good interfacial bonding) 7 Reinforcing fillers JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS .. good interfacial bonding depends on: Particle shape platelike or fibrous particles may be oriented during processing resulted in anisotropic properties. Particle size smaller, higher mechanical property (tensile) Bigger, reduced properties vs pure thermoplastic 8 ..cont. JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS .. good interfacial bonding depends on: Distribution of sizes Good distribution results in increase in mechanical properties. Surface chemistry of the particle To promote interaction with polymer for good a interfacial adhesion. 9 ..cont. JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS Classification of Fillers JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS Shapes of Fibers and Fillers JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS Shapes of Fibers and Fillers JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS ..Is the ratio of length to width of filler particles. Flakes or fibers ~ have aspect ratios that make them resist movement or realignment thus improving strength. Spheres have no aspect ratio and produce composites with isotropic
13 ASPECT RATIO JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS Shapes of Fibers ~ strength mechanism JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS 15 ..cont. Spherical Lamellar* Fibrous Sand Mica Glass fibers Quartz powder Talc Asbestos Silica Graphite Wollastonite Glass spheres Kaolin Carbon fibers Calcium carbonate Cellulose Carbon black Synthetic fibers Metallic oxides *Lamella is a term for a platelike/platelet structure, appearing in multiples JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS .. Fillers can be classified by size, 2 group: Nano-scale materials Large scale materials)
Nanocomposite (..new development Nano Technology) ..are submicron in size (<1x10 -9 m) ..late 1980s, first developed mostly in nylon ..1990s, limited application in nylon & other engineering plastics ..late 1990s, application in commodity plastics (polyolefins) ..2002, commercial automotive application General Motors ..if uniformly spread out, 5g could cover the surface of footfield ..well dispersed, 2.5% has properties of 20% talc filled! ..advantages: low thermal expansion, lighter weight, reduced flammability and improved physical properties. 16 ..cont. JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS Function The basic purpose is to 'fill' a compound (increase bulk at low cost). To do this the mix must be homogeneous, with good filler/polymer adhesion, and the filler also begins to improve mechanical properties. Most particulate fillers have a higher specific gravity than polymers, but some have been developed that can reduce the weight of the compound. Geometry and surface texture fundamentally influence adhesion properties: these can be improved by surface treatment. Properties Stiffness, hardness, shrinkage/dimensional stability: thermal stability and flame retardancy may also be improved. FILLERS At a Glance JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS Materials/ characteristics Clays, calcium carbonates, talc, silicates. Pigments such as titanium dioxide and carbon black may also have a reinforcing effect. Glass or ceramic micro spheres can also offer good properties.
Disadvantages Compounding may present problems, but surface treatments and dispersing agents will help. Solid mineral fillers add to weight.
New developments Improved surface treatments for better dispersability, multi-functions, lightweight fillers; nano-composites.
FILLERS At a Glance (cont) JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS Type Characteristic/main application Alumina trihydrate Extender: serving as flame retardant and smoke suppressant Barium sulphate Filler and white pigment: increases specific gravity, frictional resistance chemical resistance Calcium carbonate Most widely used extender/pigment or filler for plastics Calcium sulphate Extender: also enhances physical properties, increases impact, tensile, and compressive strengths Common fillers and reinforcements for plastics (cont) JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS Type Characteristic/main application Carbon black Filler: used as pigment and anti-static agent, or as an aid in cross-linking; electrically conductive Carbon/graphite fibres Reinforcement: high modulus and strength; low density, coefficient of expansion, coefficient of friction: conductive Feldspar, nepheline syenite Speciality filler: easily wetted and dispersed: gives transparency/translucency; resistant to chemicals and weathering Glass fibre Largest volume reinforcement: giving high strength, dimensional stability, heat resistance, chemical resistance Common fillers and reinforcements for plastics (cont) JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS Type Characteristic/main application Kaolin Second-largest extender/pigment by volume: mainly used in wire and cable, PVC flooring, SMC/BMC Metal fillers, filaments Electrical and/or thermal conductivity or magnetic properties; reduce friction: expensive Mica Flake-form reinforcement: improves dielectric, thermal, and mechanical properties; low in cost
Microspheres (hollow) Reduced weight; improved stiffness and impact resistance Microspheres (solid) Improved flow properties and stress distribution
Common fillers and reinforcements for plastics (cont) JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS Type Characteristic/main application Organic fillers Extenders/fillers (wood flour, nutshell, corncobs, rice, peanut hulls) Polymeric fillers lightweight Silica Filler/extender/reinforcement: makes more thixotropic, aiding plate-out in PVC; acts as flatting agent
Talc Filler/extender/reinforcement: improves stiffness, tensile strength, resistance to creep Wollastonite Improves strength, reduces moisture absorption, higher heat/dimensional stability, improved electrical properties: high loadings possible Common fillers and reinforcements for plastics (cont) JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS ..do not dissolve in the polymer matrix fillers vs fibers: ..fillers are small particles and contribute only slightly to strength ..fibers to produce dramatic improvements in physical properties (strength, impact & stiffness) ..but some materials can act as filler or fiber or both (eg: glass) 24 JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS Interface bond between matrix and reinforcements Properties of the reinforcement Size and shape of the reinforcement Loading of the reinforcement Processing technique Alignment or distribution of the reinforcement 25 JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS 1. Interface bond between matrix and reinforcement The matrix function to transfer most of the stress to the reinforcement. ..so there must be an excellent adhesion between the matrix and reinforcement. 2. Properties of the reinforcement ..vary & determine by composition, shape, size, production, handling, processing, surface enhancement & no of defects. 26 ..cont. JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS 3. Size and shape of the reinforcement ..provide superior handling, loading, processing, packing orientation or adhesion in the matrix. ..some fibers are so small & handle by bundles, others are woven in cloth. ..particulates are more likely to be randomly distributed than long fibers. 27 ..cont. JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS 4. Loading of the reinforcement ..mechanical strength depends on the amount of reinforcing agent it contains. ..eg: 60% reinforcement with 10% resin gives 6 times stronger than a part containing opposite amounts of these two materials. ..some glass filament-wound composites may have up to 80% (by wt.) loading by unidirectional orientation of the filament ..most reinforced TP composites contain less than 40% (by wt.) reinforcements. 28 ..cont. JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS 5. Processing technique ..some technique allow the fibers to be more carefully aligned or oriented. ..during processing, fibers may be broken or damaged resulting in lower mechanical properties. ..particulates & short fibers are more likely to have random rather than oriented placement in the matrix. 29 ..cont. JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS 6. Alignment or distribution of the reinforcement ..allows versatility in composites. ..the processor can align or orient the fibers to provide directional properties (eg: filament winding process ~ fishing rod). ..parallel (anisotropic/continuous strands) alignment > bidirectional alignment (cloth) > random (mat) alignment in term of strength property. 30 ..cont. JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS 32 Glass Carbonaceous (eg. Carbon, graphite) Polymer (eg. Kevlar, cellulose acetate) Inorganic (eg. Aluminium oxide, MgO 3 ) Metal (eg. Steel, aluminium)
JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS Lamina ..basic structural element of laminar composite is the lamina fibrous, six sub-classes.. Glass Carbonaceous Polymer Inorganic Metal hybrids 33 JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS Lamina ..a thin plate, sheet or layer (Polymer Dictionary) ..consist of unidirectional fibers, woven cloth, or sheets of material. Individual layer act as reinforcement.. Performance depends on lamina selection, alignment and composition. eg: random-chopped strand mat gives equal strength properties in all direction. eg: unidirectional fiber alignment has the highest strength parallel to the fiber. 34 JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS
Fibrous, six sub-classes.. Glass Carbonaceous Polymer Inorganic Metal hybrids 35 JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS Glass fibers ..most important reinforcing materials ..replacing metal parts due to better strength & light weight. How it produced? ..involves pulling a strand of molten glass tru small orifice, diameter controlled by pulling action. Glass is from silica, few types: Type E ~ good electrical properties.. Type C ~ chemical resistance. Type D ~ low dielectric constant/low density. Type I ~ contains lead oxide for radiation protection. Type S ~ for high-strength uses. 38 JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS Glass fiberstypes & forms: Rovings ~ long strands, loosely associated rope Chopped fibers ~ chopped strands from rovings; length size 3~50mm (0.125~2in) Milled fibers ~ length size < 1.5mm, produced by hammer milling glass strands, add to premix to increase viscosity & product strength. Yarn ~ resemble rovings but twisted like a rope, for large container. Woven cloth ~ for thick reinforcement. 39 JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS Carbonaceous fibers ..made by oxidizing, carbonizing & graphitizing an organic fiber like rayon & polyacrylonitrile (PAN). Rayon is natural based material made from cellulose of wood pulp or cotton. PAN is a resinous, fibrous, or rubbery organic polymer, chemically modified to make the carbon fibers found in tennis and badminton rackets, high- tech bicycles, blades for turbine & helicopter. Graphite fibers exceed glass strength, used as self-lubricating materials. 55 Reinforcementcont JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS Polymer fibers ..are used as reinforcements in belting, ties gears, etc. eg: polyester, polyamide, polyvinyl acetate (PVA) cellulose acetate (CA), etc. eg: Kevlar aramid (DuPont trademark), gives twice stiffness & half density of glass. Applications ~ mostly in composite! ..with high strength polymer matrix such as epoxy resin, polyester, phenolic etc. eg: polyester & polyamide fibers use in bulk molding compound, sheet molding compound, layup, pultrusion, filament winding 56 Reinforcementcont JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS DuPont Kevlar pulps are highly fibrillated chopped fibers that can be used as specialty additives to enhance performance by providing excellent reinforcement and viscosity control under shear stress. Kevlar pulp is used in automotive brake pads, gaskets, automatic transmission papers, and as a viscosity control additive for adhesives and sealants.
Properties Description Highly fibrillated, short (0.5-1mm) fibers Color Yellow Useful temperature range -200 to +350C Specific gravity 1.45 Specific surface area 7-11m/g Bulk density 3-7 lbs/ft JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS NEW Kevlar XP fabric technology
This patented technology provides approximately 15% reduction in backface deformation and superior ballistic performance in a 100% Kevlar solution. Kevlar XP allows more comfortable vest design with at least 10% reduction in overall weight. JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS Kevlar thread helps make fire-resistant (FR) mattresses more effective by improving the integrity of the seams between panels of flame resistant material High strength, light weight and thermal stability have made Kevlar paper a crucial building material for honeycomb cores in the aerospace industry, where it is used in parts such as cabin floors, rotor blades and engine nacelles Kevlar paper for aerospace applications Kevlar in fire resistance mattresses JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS Gloves and protective clothing made from Kevlar yarn provide superior cut, abrasion and thermal resistance for people who work with glass, sheet metal and other hazardous objects Kevlar yarn Kevlar helps protect law enforcement, corrections and military personnel from death or serious injury with an ever-growing line of products designed to help defend against ballistic projectiles, fragmentation and puncture- producing handheld weapons. Kevlar protection products JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS Polymer fiberscont eg: polyester & polyamide fibers use in; bulk molding compound (BMC) sheet molding compound (SMC) layup pultrusion filament winding resin transfer molding (RTM) reinforced reaction injection molding (RRIM) thermal expansion resin transfer molding (TERTM) injection molding operations 61 Reinforcementcont JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS Inorganic fibers ..a class of crystalline fibers. ..made from aluminum oxide, magnesium oxide, potassium titanate, silicon carbide, titanium boride etc. eg: boron fibers is used to make many composite parts for military and civilian aircraft Very costly with high tensile strength > 40 GPa Special use in dental plastics fillings, turbine compressor blades, special deep water equipments etc. 62 Reinforcementcont JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS Metal fibers ..continuous filaments from steel, aluminum etc. Used for added strength, heat transfer, and electrical conductivity.
Hybrid fibers ..two or more fibers are combined (hybridization) to tailor the reinforcement to needs of the designer. eg: glass & carbon fibers are used together to increase impact strength & toughness, reduce cost (i.e not 100% carbon fiber) 63 Reinforcementcont JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS Overview of wide variety of composite parts used in the Air Forces C-17 transport. It uses 15000 lb of advanced composites ..think about it! JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS ..in general JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS NATURAL FIBERS JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS The flax plant (Linum usitatissimum) is the source of two products: flaxseed for linseed oil and fiber for linen products. Plants with two distinct types of growth are used for seed and fiber production. JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS Hemp (Cannabis sativa) JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS Jute is a long, soft, shiny vegetable fiber that can be spun into coarse, strong threads. It is produced from plants in the genus Corchorus, family Tiliaceae. JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS Sisal (Agave sisalana) is an agave that yields a stiff fiber traditionally used in making twine, rope and also dartboards. JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS The main uses of kenaf fiber have been rope, twine, coarse cloth (similar to that made from jute), and paper. In California, Texas and Louisiana, 3,200 acres (13 km) of kenaf were grown in 1992, most of which was used for animal bedding and feed. Uses of kenaf fibre include engineered wood, insulation, and clothing-grade cloth.
Panasonic has set up a plant in Malaysia to manufacture kenaf fibre boards and export them to Japan, oil and liquid absorbent material, soil-less potting mixes, animal bedding, packing material, cut bast fiber for blending with resins for plastic composites, as a drilling fluid loss preventative for oil drilling muds, for a seeded hydromulch for erosion control and various types of erosion and environmental mats, such as seeded grass mats for instant lawns and moldable mats for manufactured parts and containers Hemp (Cannabis sativa) JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS Coir ~ The fiber obtained from the husk of a coconut, used chiefly in making rope and matting JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS JULY2010 Polymer UniKL CRB 30503 POLYMER ADDITIVES & BLENDS 80