B.T Astrom Aw Manufacturing | F : : ee ees eee ee ee ee e ne ee de eet ees ee te! Sy fee e1 52 Manufacturing of Polymer Composites To Carol and Sara, who each in their own way made this book possible Manufacturing of Polymer Composites B T Astrém Department of Aeronautics Royal Institute of Technology Stockholm Sweden Gi CHAPMAN & HALL London - Weinheim - New York - Tokyo - Melbourne - Madras Published by Chapman & Hall, 2-6 Boundary Row, London SE1 8HN, UK Chapman & Hall, 2-6 Boundary Row, London SE1 8HN, UK Chapman & Hall GmbH, Pappelallee 3, 69469 Weinheim, Germany Chapman & Hall USA, 115 Fifth Avenue, New York, NY 10003, USA Chapman & Hall Japan, ITP-Japan, Kyowa Building, 3F, 2-2-1 Hirakawacho, Chiyoda-ku, Tokyo 102, Japan Chapman & Hall Australia, 102 Dodds Street, South Melbourne, Victoria 3205, Australia Chapman & Hall India, R Seshadri, 32 Second Main Road, CIT East, Madras 600 035, India First edition 1997 © 1997 B Tomas Astrém Typeset in 10/12 pt Palatino by GreenGate Publishing Services, Tonbridge, Kent Printed in Great Britain by St Edmundsbury Press, Bury St Edmunds, Suffolk ISBN 412 81960 Apart from any fair dealing for the purposes of research or private study, or criticism or review, as permitted under the UK Copyright Designs and Patents Act, 1988, this publication may not be reproduced, stored, or transmitted, in any form or by any means, without the prior permission in writing of the publishers, or in the case of reprographic reproduction only in accordance with the terms of the licences issued by the Copyright Licensing Agency in the UK, or in accordance with the terms of licences issued by the appropriate Reproduction Rights Organization outside the UK Enquiries concerning reproduction outside the terms stated here should be sent to the publishers at the London address printed on this page The publisher makes no representation, express or implied, with regard to the accuracy of the information contained in this book and cannot accept any legal responsibility or liability for any errors or omissions that may be made A catalogue record for this book is available from the British Library Printed on acid-free text paper, manufactured in accordance with ANSI/NISO Z39.48-1992 (Permanence of Paper) CONTENTS Preface Acknowledgements Nomenclature Abbreviations and Acronyms INTRODUCTION 1.1 The Evolution of Materials 1.2 The Composite Concept 1.3 Design and Manufacturing 1.4 Market 1.5 Application Examples 1.5.1 Transportation Applications 1.5.2 Marine Applications 1.5.3 Aerospace and Military Applications 1.5.4 Construction Applications 1.5.5 Electrical and Sanitary Applications 1.5.6 Sports Applications 1.5.7 Other Applications 1.6 Book Contents 1.7 Outlook 1.8 Summary References CONSTITUENT MATERIALS 2.1 Matrices 2.1.1 Polymer Morphology 2.1.2 Structural Aspects Influencing Properties 2.1.2.1 Intramer Structure 2.1.2.2 Intramolecular Structure 2.1.2.3 Intermolecular Structure 2.1.3 Polymer Properties 2.1.3.1 Thermal Properties of Solid Polymers 2.1.3.2 Mechanical Properties of Solid Polymers 2.1.3.3 Other Properties of Solid Polymers 2.1.3.4 Properties of Liquid Polymers 2.1.3.5 Healing of Polymers 2.1.3.6 Liquid Crystalline Polymers vi Contents 2.1.3.7 Elastomers Types 2.1.4 Polymers as Composite Matrices 2.1.5 Thermoplastic Polymer Matrices 2.1.5.1 Polyethylenes 2.1.5.2 Polypropylenes 2.1.5.3 Polyamides 2.1.5.4 Thermoplastic Polyesters 2.1.5.5 Poly(phenylene Sulfides) 2.1.5.6 Polyketones 2.1.5.7 Polysulfones 2.1.5.8 Thermoplastic Polyimides 2.1.6 Thermoset Polymer Matrices 2.1.6.1 Unsaturated Polyesters 2.1.6.2 Epoxies 2.1.6.3 Vinylesters 2.1.6.4 Phenolics 2.1.6.5 Other Thermosets 2.1.7 Matrix Forms 2.1.8 Additives 2.2 Reinforcements 2.2.1 Glass Fibers 2.2.2 Carbon Fibers 2.2.3 Aramid Fibers 2.2.4 Polyethylene Fibers 2.2.5 Other Fibers 2.2.6 Reinforcement—Matrix Interaction 2.2.7 Fibrous Reinforcement Forms 2.2.7.1 Weaving 2.2.7.2 Noncrimp Fabrics 2.2.7.3 Knitting 2.2.7.4 Braiding 2.2.7.5 Mats and Non-Wovens 2.2.7.6 Combination Fabrics and Preforms 2.3 Preimpregnated Reinforcement 2.3.1 Solvent Impregnation 2.3.2 Melt Impregnation 2.3.3 Powder Impregnation 2.3.4 Commingling 2.3.5 Comparison of Preimpregnated Reinforcement 2.3.6 Molding Compounds 2.4 Core Materials 2.4.1 Wood Cores 2.4.2 Honeycomb and Corrugated Cores 2.4.3 Expanded Foam Cores