CDB 4423 POLYMER PROCESS ENGINEERING

Experiment 3 Composite

No Name ID Number
1 Hussien Alkaff 19496
2 Mohamad Alif bin Roslan 19428
3 Mohamad Nur Salam bin Mohd Yunus 19315
4 Wan Intan Nadiah binti Borharuddin 18857

Group Number : Group 1

Date of Experiment : 15th June 2017
Date of Submission : 3rd July 2017
INTRODUCTION
Composite is defined as a material composed of two or more different materials, with the
properties of the resultant material being superior to the properties of the individual materials
that make up the composite. Composites are made from matrices of epoxy, unsaturated
polyester and some other thermosets, and a few thermoplastics. The reinforcements are glass,
graphite, metal and ceramic.

Hand lay-up is an open contact molding in one-sided molds are the lowest cost and most common
processes for making fiberglass composite products and is the most common method of
producing composite materials.

Although epoxy resins are very attractive due to their high strength, stiffness, high temperature
resistance, low volatility and good adhesion to metal and ceramic, as organic polymers, they are
very vulnerable to the absorption of surrounding media of either liquid or gasses which can
diffuse into the polymer matrix causing a reduction of their mechanical properties. Therefore,
determination of water absorption will be carried out.

OBJECTIVE
To study on the concept of composite material and the formation of composite material.
To study the effect of curing temperatures on mechanical properties of composite.

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LITERATURE REVIEW
Capillaries and micro-cavities usually exist within the polymer composite which allow water to
bound in it by the strong interactions with the polymer (Mikols, Seferis, Apicella, & Nicolais,
1982). The absorption of water might be caused by the processing condition of the polymer such
as curing temperature. Pethrick et al. (1996) in his study confirms that with increasing of the
temperature of cure will cause more amount of water absorb into an epoxy resin. The analysis of
the dielectric data at low and high frequency reveals that the water molecules are bound within
the matrix to different extents. The high frequency signature can be associated with free water,
whereas the lower frequency signature is associated with bound water. As the cure temperature
is increased, the amount of free water increases and the diffusion coefficient is observed to
decrease. These changes are consistent with the higher temperature increasing the extent of
reaction and also producing a high content of micro-voids. The problems of surface effects and
the microstructure of the polymer next to the electrode make the interpretation of the apparent
diffusion coefficients qualitative.

Absorption of water into the composite will somehow change the properties of the composite
which then tend to affect the performance of the polymer. Existence of water in the composite
have been taking interest from a lot of researchers as they want to study about how water
content in polymer could reduce or increase the mechanical properties of it. In a study by Dhakal,
Zhang, and Richardson (2007), they claims that as a result of water absorption, the cellulose
content of the reinforcement fibre was reduced when the water molecules embedded
themselves between the polymer chains. This made the structure of the fibre more flexible.
Other study by Maslinda, Abdul Majid, Ridzuan, Afendi, and Gibson (2017) compare the
mechanical properties between dry and saturated of woven fiber samples in their study and
found out that the tensile properties of the composites were reduced because of the water
absorption. The tensile strength and tensile modulus of the samples have significance reduction
with the allowance of more amount of water being absorbed through increase of immersion
time.

With the study stated above, we will demonstrate the effect of water absorption to the
mechanical properties of the composite polymer, which in specific, the glass fiber composite.

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PROCEDURE
Preparation of Sample

1. The mold (glass) is first waxed.

2. The fiber glass mat is cut and 2 pieces of fiber glass mat are laid into the mold.
3. Epoxy with molecular weight EPOLAM 50, MW 700 g/mol is mixed with diamine with MW
448 g/mol until gel time is reached. The ratio of difunctional epoxy/diamine is 20/6.4 (wt/wt)
and 20/10 (wt/wt).
4. The epoxy resin is poured onto the fiber glass and the composite is flatted using roller. The
composite is then left for around 10 minutes.
5. The composite is cut into dimensions of 50 mm x 50 mm x 3 mm (at least 4 samples are
prepared for two different curing temperatures).
6. Two samples are allowed to react (cure) at room temperature for 24 hours and another two
are allowed to react (cure) at 120 C for 2 hours in the oven. These samples are used for water
absorption.

Water Absorption

1. All samples are polished to ensure a flat surface.

2. Their initial weights are obtained at room temperature.
3. The dimension of each sample, average of thickness, length and width are measured at room
temperature before immersion. The data are measured again after 1 week immersion in
water.
4. The samples are immersed in water at room temperature and 50 C and then are removed
periodically from the water bath, wiped with tissue paper and weighed before immersing the
samples again. These steps to be repeated for one week period.
5. The amount of water absorbed by the sample is calculated using the following equation

0
(%) = 100%
0

Mt is water content at any given time

Wt is sample weight at the time of measurement

W0 is initial sample weight

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RESULT AND DISCUSSION
Epoxy: Curing Water bath
W0 (g) W1 (g) W2 (g) W3 (g)
Amine Ratio temperature (oC) temperature (oC)
25 4.9888 5.00 5.04 5.06
25
50 4.6744 4.74 4.79 4.81
20/6.4
25 6.0565 6.37 6.61 6.70
120
50 6.5555 7.55 7.62 7.71
25 6.1022 6.12 6.14 6.15
25
50 6.3979 6.49 6.56 6.71
20/10
25 5.2286 6.17 6.32 6.49
120
50 4.4069 5.50 5.77 5.84

Total
Curing Water bath Total weight
Epoxy:Amine Ratio Weight
temperature (oC) temperature (oC) increase (g)
increase (%)
25 0.07 1.43
25
50 0.14 2.90
20/6.4
25 0.64 10.62
120
50 1.15 17.61
25 0.05 0.78
25
50 0.31 4.88
20/10
25 1.26 24.13
120
50 1.43 32.52

1. Write down your observation. Explain how the curing temperature may affect the water
absorption of epoxy resin.

Based on the calculated table, water absorption increases as the curing temperature increases.
The above study confirms that increasing the temperature of cure has the effect of increasing
the amount of water sorption in an epoxy resin. As the cure temperature is increased, so the
amount of free water increases and the diffusion coefficient is observed to decrease. These
changes are consistent with the higher temperature increasing the extent of reaction and also
producing a high content of micro-voids(Richard A. Pethrick*, 1995).

The absorption and diffusion of water in polymeric materials such as epoxy systems is related to
the free volume and the polymerwater affinity. The increase of curing temperature will
contribute to the increase of free volume occurring upon curing, thus more water can be
absorbed into the epoxy resin(A. F. Abdelkader, 2005).

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2. Explain how the arrangement of fiber can affect the modulus and strength of composite
materials.

The arrangement of fiber in composite effects the strength and modulus of the composite by
producing a strong bond between the fiber and epoxy resin. Shear loading at the interface is
transmitted from the epoxy resin to the fiber glass. The arrangement or orientation of the fibers
relative to one another, the fiber concentration, and the distribution all have a significant
influence on the strength and other properties of fiber-reinforced composites.

With respect to orientation, two extremes are possible: (1) a parallel alignment of the
longitudinal axis of the fibers in a single direction, and (2) a totally random alignment. Continuous
fibers are normally aligned, whereas discontinuous fibers may be aligned, randomly oriented, or
partially oriented. Better overall composite properties are realized when the fiber distribution is
uniform.

Aligned fibrous composites are inherently anisotropic, in that the maximum strength and
reinforcement are achieved along the alignment (longitudinal) direction. In the transverse
direction, fiber reinforcement is virtually nonexistent: fracture usually occurs at relatively low
tensile stresses. For other stress orientations, composite strength lies between these
extremes("Composites," 2005).

3. Explain how the curing temperature may affect the water absorption and other mechanical
properties.

Water absorption increases with increasing in curing temperature. When the curing temperature
is increased, the flexural and tensile strength of the composite decreases. As a result of water
absorption, the cellulose content of the reinforcement fiber was reduced when the water
molecules embedded themselves between the polymer chains. This made the structure of the
fiber more flexible, correspond with the decreasing in the tensile strength of the composite.

4. Using the literature values, obtain the density and modulus for DGEBA epoxy resin and fiber
glass (E-Glass). Calculate the theoretical modulus of your composite sample. (Using the
known volume and known density of epoxy, calculate the theoretical weight of epoxy
without fibers.)

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5. What are the advantages of using thermoset as matrix as compared to thermoplastic?

There are advantages of using thermoset compare to thermoplastic. Firstly, thermoset will cure
at lower temperature than temperature that thermoplastics will melt. This allows thermosets to
be manufactured at lower temperature compare to thermoplastics. Secondly, thermoset
significantly improve the materials mechanical properties, providing enhances chemical
resistance, heat resistance and structural integrity through cross-link. Besides, thermosets often
provide easy wetting of reinforcing fiber and easy forming to final part geometries.

6. Which one is more suitable for making aircraft body, epoxy/glass or epoxy/carbon fibers?
Explain your answer.

Epoxy/carbon fibers is more suitable to make aircraft body. This is because epoxy/glass has low
stiffness. The important design properties of carbon composites are their high strength-to-weight
and stiffness-to-weight ratios. With proper selection and placement of fibers, composites can be
stronger and stiffer than steel parts with similar thicknesses but 40 to 70% less weight. Fatigue
resistance of continuous-fiber composites is excellent, and chemical resistance is better than that
of glass-reinforced composites, particularly in alkaline environments. Thermal characteristics of
carbon fibers differ from those of almost all other materials. It allows design of structures with
zero or very low linear and planar thermal expansion.

7. Give ONE application of composite material based on glass, carbon and aramid fibers.
Explain your answer.

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REFERENCES
A. F. Abdelkader, J. R. W. (2005). Water Absorption in Epoxy Resins: The Effects of the Crosslinking
Agent and Curing Temperature. Water Absorption in Epoxy Resins, 2543-2549.

Composites. (2005) Materials Science and Engineering Introduction (pp. 577).

Dhakal, H. N., Zhang, Z. Y., & Richardson, M. O. W. (2007). Effect of water absorption on the
mechanical properties of hemp fibre reinforced unsaturated polyester composites.
Composites Science and Technology, 67(7), 1674-1683.

Maslinda, A. B., Abdul Majid, M. S., Ridzuan, M. J. M., Afendi, M., & Gibson, A. G. (2017). Effect
of water absorption on the mechanical properties of hybrid interwoven cellulosic-
cellulosic fibre reinforced epoxy composites. Composite Structures, 167, 227-237.

Mikols, W. J., Seferis, J. C., Apicella, A., & Nicolais, L. (1982). Evaluation of structural changes in
epoxy systems by moisture sorption-desorption and dynamic mechanical studies.
Polymer Composites, 3(3), 118-124.

Pethrick, R. A., Hollins, E. A., McEwan, L., Pollock, A., Hayward, D., & Johncock, P. (1996). Effect
of cure temperature on the structure and water absorption of epoxy/amine thermosets.
Polymer International, 39(4), 275-288.

Richard A. Pethrick*, E. A. H., lain McEwan, Elizabeth A. Pollock,. (1995). Effect of Cure
Temperature on the Structure and Water Absorption of Epoxy/Amine Thermosets. 275-
288.