Mehdi Farshad

Composite Structures:

Materials, Applications, Examples, Computations, Tends

Prof. Mehdi Farshad

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Composite materials

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Classification of materials

1. Organic materials• Natural substances• Synthetic materials

• Biological materials

2. Anorganic materials• Minerals including ceramics

• Metals

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Definition of polymeric materials

• Materials constituted of long molekular chains (macromolekuls) • Organic connections (Polymers)

through:Processing of natural productsor throughSynthesis of primary materials from oil, gas or coal

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Synthetic materials

• Plastomers (Thermoplasts)

• Duromers (Duroplasts)

• Elastomers (Elaste)

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Character of polymeric materials

Thermoplasts

•"Spagetti"- Structure

• strong softening withtemperature; reversible hardening

• Medium strength

• Large deformation capacity

Elastomers

• loose spacial cross-links

• Flow at high temperature

• small strength

• large strain capacity

Duroplasts

• Strong croos-link

• No softening withtemperature

• High strength

• Small straincapacity

Thermoplastic Elastomers• Rubber elastic

• Medium strength

• Large strain capacity

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Thermoplastic Elastomers• TPU

Examples of polymeric materials

Thermoplasts

• Polyvinylchloride (PVC)

• Polyethylene (PE)

• Polypropylene (PP)

• Polycarbonate (PC)

• Polymethylmethacrylate(PMMA)

Elastomers

• Natural rubber(Kautschuk)

• Synthetische rubbers

• Polyurethane (PUR)

• Plastizised PVC (PVC-P)

Duroplasts

• GF-UP

• GF-EP

• GF-VI

• PUR

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Constitution of polymeric materials

Basic polymericmaterial

Additives

• Stabilizators• Modificators• Colors, Pigments• Softeners• Fire protection agents• Antistatica• Friction reducing agents• Special additives• Coupling agents

Fillers

Reinforcement components

• Fibers• Mats• Paricles

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General features of polymers

• Resistance to chemicals

• Corrosion resistance

• Thermal and electrical insulation

• Light-weight with varying degrees of strength

• Processing possibilities: thin fibers or very intricate parts

• Ease and versatility of production of plastics products

• Multifunctionality

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Engineering polymers

Materials:• Thermoplastics• Duroplastics• Composites, laminates• Structured foams• Elastomers• Polymer alloys

Examples:• Polycarbonate, Polyamide• Polyester, Epoxy• GFRP, CFRP• Polyurethane, PVC• Natural rubber, TPE• PVC/ABS, PVC/Arcylic

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Production methods of polymeric products

• Extrusion

• Extrusion-based methods

(Production of profiles, blasing methods, coating methods, coextrusion)• Resin infusion technique

• Thermo-forming

• Calendaring

• Spin moulding

• Pressure moulding (SMC) • Resin Tranfer Moulding (RTM)

• Glass Mat Moulding (GMT)

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Applications of polymeric materials

• Commodities Caffee mashines, television• Transport Automobiles, aircrafts, ships• Medicine Prosthetic devices, tubes• Sport and leisure Ski, clothing• Safety Safety systems• Science Scientific instruments• Communication Optical fibers, Antanna• Lifelines Piping systems• Structures Bridges, buildings

Today, our life without polymers cannot be immagined !

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Composite materials

Definition:Material made of two or more components, each of which mayfulfill certain function

Functions of the constituents:• Enhancement of mechanical properties (reinforcement)• Improvment of physical, thermal, electrical, magnetic

properties• Improvement of chemical resistance• Sensors, and actuators

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Features of composite materials

(1) Light weight(2) High strength and high stiffness(3) Chemical resistance(4) Specific thermal, electric, and magnetic functions(5) Corrsion resistance(6) Potential multi-functional applications(7) Potentials for rehabilitation of existing materialssystems

(buildings, bridges, pipelines, …)

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Light-weight structures

Definition:

Structural elements and systems that fulfill the prescribed requirements

(strength, stiffness, stability, thermal, chemical, electromagnetic, etc.)

with less weightthan other comparable elements and systems

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Types of composite materials

• Natural composites (wood, bone, …)• Polymer-based composites• Metal-metal composites• Ceramics-based composites• Hybrid composites (polymer, ceramics, metal)• Chemically-bond composites

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Types of composition

• Particle reinforced composites

• Continuous fiber reinforced composites

• Discontinuous (chopped) fiber reinforced composites

• Chemical composition

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Fiber reinforced composites

• Fiber reinforcements- Continuous fibers- Short (chopped fibers)- Woven fabrics

• Particulate composites- Macroparticles- Nano particles

Types of fibers:- Natural (cellulose)- Synthetic (Polyester, PE, PBO-Zylon, Aramid)- Mineral (asbestos)- Glass, Carbon, Kevlar- Metal fibers (Tungston, etc.)- Non-metallic (Boron, etc.)

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Examples of components of reinforced polymers

• Fibers- Glass

- Graphite (carbon)

- Aramid /Kevlar

Matrix:- Polyester

- Epoxy

- Vinylester- Thermoplastic resins (e.g. Polypropylene)

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Types of fiber-reinforced composites

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Laminate lay-up

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Carbon Nanotube

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Spiral nanotubes- telephone cords

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Carbon nanotubesstudies using Raman Spectroscopy, AFM/EFM, SEM, EBPG, FIB technologies

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Formation of kink in the nanotube

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Bending and buckling of nanotubes

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Bending and buckling of nanotubes

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Definition of nanocomposites

Polymer/inorganic nanocomposites are composed of two or more physically distinct componentswith one or more average dimensions smaller than 100 nanometers.

Role of inorganic filler ( particles or fibers):

To provide intrinsic strength and stiffness

Role of the polymer matrix:

• Adhere to and bind the inorganic component

• protect the surface of the filler from damage and hinder crack propagation.

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Potential applications of nanocomposites

• Gas barriers• Oxygen barriers• Food packaging• Fuel tanks• Films• Surfaces• Flammability reduction

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Applications of composite materials

• Aerspace and aircraft industies• Automotive industry• Marine applications, (ships, floating docks, …)• Sport and recreational industry (clothing, bicycle, ski, …)• Household appliances• Electrical appliances, computers, …• Architectural applications• Structural applications (buildings, bridges,…)• Energy generation (windmills, …)• Energy and material trasnport• Lifelines (pipelines)• Retrofitting of structures• Biomedical applications (devices, instruments, …)• Multifunctional applications (Antenna,…)• Intelligent material systems (Sensors, actuators, …)

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Examples of composite structures

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Windmills

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Retrofitting of bridge piers with CFRP strips

Mehdi FarshadComposite profile made of glass fiber reinforced polymers

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Glass fiber reinforced (centrifugally cast) pipes

Glass fiber/polyester composite pipe

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Glass fiber /polyester (vinylester) filament wound pipes and basin

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Composite antenna coverage systemSäntis, Switzerland

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Large prefabricated composite elements for antenna protection

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Mount Säntis in Switzerland

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Goal

Conception and construction of a functional structural system for antenna protection

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Engineering Aspects

(1) Procedure for systematic engineering planing

(2) Setting-up of technical requirements(3) Choice of an appropriate material

(4) Choice of the size and the geometry of the structural element

(5) Design of connections to the structural system

(6) Material and system tests

(7) Dimensioning and analysis of the system behavior(8) Choice of the production method

(9) Means of transport (local and global)

(10) Method of installation

(11) Stages of supervision

(12) Acceptance tests/criteria(13) Long-term monitoring (Health monitoring)

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Requirements on the material and the structural system

• Radio-electrical transparency

• Short-term and long-term strength, stiffness, and stability

• Water and vapour-tightness

• Resistance againts external impacts, including hail

• Fire resistance

• Favorable environmental properties

• Construction, transport, and installation in one piece

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Environmental effects

• Wind forces (pressure, suction)- Wind speed up to 240 km/h

• Thermal effects; Temperature gradient- internal und external up to 60°C

• Snow and Ice

• Water and vapour diffusion

• Hail

• Fire

• Interaction with the whole structural system (steel framework, etc.)

• UV-Radiation

• Weathering

• Fungi und micro-organisms

• Dynamical loading during transport and installation

• Short-term and Long-term effects

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Wind simulation test on the sandwich element

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Assemblage of the foam segments of the sandwich elements on a wood form

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Hand lamination of the inner side of the sandwich element

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Hand lamination of the outer side of the sandwich element

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Vaccuming of the outer facing laminate of the sandwich element

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Spraying of the outer surface with PUR coating

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Lifting of the sandwich element with a crane to the side of the cable car

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Local transport of the sandwich element with cable car fromthe base station(Schwägalp) to the top of the Mount Säntis

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Local transport of the sandwich element in the construction site

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Local transport of the sandwichelementin the construction site-Installtion on the steel framework

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Local transport of the sandwich element in the construction site-Installtion on the steel framework

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A detailed view of part of the sandwich element showing boltedconnections and water-tightness GFRP shell

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South-west view of the antenna protection system on Mount Säntis perior to extention works

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South-west view of the antenna protection system on Mount Säntis during the extension works

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South-west view of the new antennaprotection system on Mount Säntis

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Composite pipes

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Glass fiber /polyester (vinylester) filament wound pipes

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Glass fiber /polyester (centrifugally cast) pipes

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ADAPwww.RohrIng.chwww.RohrIng.chwww.RohrIng.chwww.RohrIng.ch

Prof. M. Farshad

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ADAPAutomated Design and Analysis of Pipelines

Versatile, Professional Pipeline Engineering Program

New Version: ADAP-E2 / 2004

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ADAP - Softwre for:

• Stress and strain analysis

• Determination of long term deformations

• Stability analysis (buckling)

• Determination of safety factors

• Determination of longitudinal effects (forces and deformations)

• Assessment of pipelines

• Failure analysis

• Determination of residual life

• Health Monitoring

• Dimensioning (design)

• Long term extrapolationShort t

erm

and

Long term

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Pipe materials types

• Single layer pipes

• Laminated pipes

• Multilayer pipes

• Structured pipes

• Sandwich pipes

• Fiber cement pipes

• Concrete pipes

• Metallic pipes

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Types of pipelines

• Buried pipes

• Pressure pipes

• Pressureless pipes

• Sewerage pipes

• Gas pipes

• Cable protection pipes

• Pipes on supports

• Concrete embedded pipes

• Pipe liners

• Heated water transport pipes

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Conformity with standards and guidelines

including:• EN 1295-1:1997• Pr EN 1295:1994• NEN EN 1295:1994• SN EN 1295-1*SIA 190.101:1997• SIA 190:2000• DIN EN 1295-1:1997• OENORM EN 1295• Entwurf prEN 14801:2003• ISO 9080:2003• ISO 10928:1997• EN 705:1995

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Loading

• Internal pressure

• Temperature gradient

• Pipe sinking

• Pipe bending

• Partial settlement

• Point load

• Surface load

• Water hammer

• Soil pressure

• Traffic load

• External water pressure

• Self weight

• Water-filling

• Buoyancy

• Residual stresses

• Initial strain

• Initial deformations

• Earthquake

• Fatigue

• Load combinations

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Long term extrapolation

Health monitoring

Residual life

Material data

Soil data

Embedment

Pipeline data

Loads

Analysis of pipelines

Design of pipelines

INPUT

INPUT

Safety factors

Pipe properties

Trench conditions

• Pipe dimensions • Embedment

parameters

Data bank

User Manual

ADAP-D2: Program Moduls

Informative moduls

Programs

Requirements

Pipe geometry

Pipe types: • Single layer • Multilayer • Structured

Results

Failure analysis

Assessment of pipeline

Axial effects

Buckling loads

• Stresses • Strains • Deflections • Safety factors

Job details

Results

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Fabrication processes

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FABRICATION PROCESSES FOR LAMINATES AND COMPOSITE ELEMENTS

1. Open mould, hand lay-up composite fabrication

2. Open mould, spray-up composite fabrication

3. Hot-melt prepregging process

4. Autoclave moulding

5. Autoclave press moulding

6. Blow moulding

7. Resin infusion method

8. Sheet Moulding Compound (SMC)

9. Compression moulding with matched metal dies

10. Filament winding process

11. Pulltrusion process

12. Thermoplastic moulding process

13. Resin transfer moulding (RTM) process

14. Glass Mat Technique (GMT)

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Open mould, hand lay-up composite fabrication

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Open mould, hand lay-up or machine lay-up method

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Compression moulding with matched metal dies

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Filament winding process

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Coextrosion

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Injection moulding process

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Trends

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Contribution of Plastics to Sustainable Contribution of Plastics to Sustainable DevelopmentDevelopment

Economic Development

Social Progress

Environmental Protection

Werner Prätorius, President APMEPlastics Forum 2003Plastics Forum 2003European Parliament, Brussels13 June 2003

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Relative importance of metals, polymers, ceramics, and composites as a function of time

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European Markets for Plastics

Furniture3%

Mechanical Engineering

2%

Leisure3%

Housewares4%

Clothes and shoes

1%

Other transports1%

Automotive8%

Others13%

ElectricalsElectronics

9%

Construction22%

Packaging31%

Medical1%

Agriculture2%

David Williams, President EuPcPlastics Forum 2003Plastics Forum 2003European Parliament, Brussels13 June 2003

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Plastics consumption by marketin Western Europe

02468

101214161820

Packag

ing

Consu

mer pr

oducts

Constru

ction

Electri

cals &

Electro

nicals

Transp

orts

Agricu

lture

Not id

entifie

d

20002010

million tonnes

David Williams, President EuPcPlastics Forum 2003Plastics Forum 2003European Parliament, Brussels13 June 2003

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Plastics Processingin the European Union

90

95

100

105

110

115

120

125

1995 1996 1997 1998 1999 2000 2001 2002 2003

Seasonally adjustedTrend-cycle

Forecast

Year on year change (%)

10.0-0.5

2003

(Forecast)

2002 2001

Source historicals: Eurostat

Production volume indexes, base 1995=100

David Williams, President EuPcPlastics Forum 2003Plastics Forum 2003European Parliament, Brussels13 June 2003

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Source: Kunststoffe, 12.2004

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Final consumption of 25,395,000 tonnes represents plastics processors' consumption of 25,905,000 tonnes less trade in semi-finished and finished plasticsproducts (420,000 tonnes) and less finished goods containing plastics (90,000 tons)

Plastics StatisticsTaken from APME - All figures in '000 tonnes

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Thank you for your attention