Thermosets and Composites

Material Selection, Applications, Manufacturing and Cost Analysis

Michel Biron

• Publisher: William Andrew
• Year: 2013
• eBook ISBN: 9781455731251
• Edition: 2
• Topic: Technology & Engineering
• Subtopic: Materials Science
• Index: Technology & Engineering

This book bridges the technology and business aspects of thermosets, providing a practical guide designed for engineers working in real-world industrial settings. The author explores the criteria for material selection, provides information on material properties for each family of thermosets, and discusses the various processing options for each material type. He explains advantages and disadvantages of using thermosets and composites in comparison to competing materials and assesses cost aspects, enabling the reader to balance out technical and economic constraints when choosing a thermoset and processing technology for a given application.This second edition contains a new section on composites solutions for practical problems, gathering information on trends contributing to the breakthrough of composites in various sectors. Other new sections on specific crosslinking processes, processing trends, machinery and equipment manufacturers, applications, bio-sourced thermosets and natural fibers, and recycling of thermosets and composites are included. Case studies are provided, illustrating many design and production challenges. Furthermore, new market data and information about health and safety will be added. All data is fully updated throughout, with pricing in USD and EUR, and both ASTM (North American) and European standards.Thermosets and Thermoset Composites, Second Edition is the only book that gives in-depth coverage of a wide range of subject matters and markets, yet in brevity and concision in a single volume, avoiding the need of consulting a series of other specialized books. By providing the knowledge necessary for selecting a fabrication process, thermoset material and methods for determining the all important cost of thermoset parts this new edition is an invaluable decision-making aid and reference work for practitioners in a field with growing importance. - Combining materials data, information on processing techniques, and economic aspects, Biron provides a unique end-to-end approach to the selection and use of materials in the plastics industry and related sectors - New material on bio-sourced thermosets, natural fibers, and recycling of thermosets - Concise and easy-to-use source of information and decision-making aid

1

Outline of the Actual Situation of Plastics Compared to Conventional Materials

Abstract

The decision to use a new material has technical, economic, and environmental consequences. The goal of this chapter is to help clarify quickly the use, possibilities, and problems of thermosets and composites. Consumptions, engineering and specific properties, costs of plastics and composites, are compared with metals and some other conventional materials.

After some basic reminders concerning thermosets, thermoplastics, composites, and related processing methods, the designer’s main problems are examined, taking into account the economic, technical, marketing, sustainability, and environmental requirements. Recycling, plastics of renewable sources and some weaknesses of polymer materials end this chapter.

The final choice of the design team will result from many iterations concerning the functional properties, the environmental constraints, the possibilities to produce the part in the required quantities, and the price. Market study specialists, associations and institutes are quoted to ease in-depth studies by the reader.

Keywords

composite; consumption; environment; market; metals; plastics; price; processing; properties; sustainability; thermoset

Chapter Outline

1.1 Polymers: The Industrial and Economic Reality Compared to Traditional Materials

1.1.1 Plastic and Metal Consumption

1.1.2 Mechanical Properties

1.1.2.1 Intrinsic Mechanical Properties

1.1.2.2 Specific Mechanical Properties

1.1.3 Thermal and Electrical Properties

1.1.4 Durability

1.1.5 Material Costs

1.1.5.1 Cost Per Weight of Various Materials

1.1.5.2 Cost per Volume of Various Materials

1.1.5.3 [Performance/Cost Per Liter] Ratios of Various Materials

1.2 What are Thermosets, Composites, and Hybrids?

1.2.1 Thermosets

1.2.2 Polymer Composites

1.2.3 Hybrid Materials

1.3 Plastics: An Answer to the Designer's Main Problems

1.3.1 Economic Requirements

1.3.2 Technical Requirements

1.3.3 Marketing Requirements

1.3.4 Sustainability and Environmental Requirements

1.3.5 Some Weaknesses of the Polymer Materials

1.4 Outline of the Technical and Economic Possibilities of Processing

1.4.1 Thermoset Processing

1.4.1.1 Molding the Solid Thermosets

1.4.1.2 Molding the Liquid Thermosets

1.4.1.3 Secondary Processing

1.4.2 Composite Processing

1.4.2.1 Primary Processes

1.4.2.2 Secondary Processing

1.4.2.3 Repair Possibilities: A Significant Composite Advantage

1.4.3 Hybrid Processing

1.5 Environmental Constraints

1.5.1 Toxicity and Pollution

1.5.2 The Recycling of Polymers

1.5.3 Development of Thermosetting Bio-Plastics from Renewable Sources

1.6 The Final Material/Process/Cost Compromise

1.7 Useful Source Examples for Initiation of In-Depth Studies

No engineer or designer can be ignorant of plastics, but the decision to use a new material is difficult and important, since it has both technical and economical consequences. It is essential to consider:

• The actual penetration of the material category in the industrial area.

• The abundance or scarcity of the material and the process targeted.

• The functionalities of the device to be designed.

• The characteristics of the competing materials.

• The cost.

• The processing possibilities.

• The environmental constraints.

The goal of the facts and figures that follow is to help clarify the real applications for thermosets and composites and the relative importance of the various material families and processes involved.

1.1 Polymers: The Industrial and Economic Reality Compared to Traditional Materials

1.1.1 Plastic and Metal Consumption

Usually, material consumption is considered in terms of weight (Table 1.1), but it is also interesting to examine:

• The consumption or production in terms of volume (Table 1.2), which is most important for fixed part sizes.

• The consumption linked to the rigidity of the engineering materials (Table 1.3).

Table 1.1

World Consumption or Production by Weight (Million Tons)

1970-2010 According to worldsteel.org & IAI.org

Table 1.2

World Consumption or Production in Terms of Volume (Million m³)

Table 1.3

World Consumption at Equal Tensile Stress (Million m^3∗ ...

Table of contents

• Cover image
• Title page
• Table of Contents
• Copyright
• Disclaimer
• Acronyms and Abbreviations
• 1. Outline of the Actual Situation of Plastics Compared to Conventional Materials
• 2. The Plastics Industry: Economic Overview
• 3. Basic Criteria for the Selection of Thermosets
• 4. Detailed Accounts of Thermoset Resins for Molding and Composite Matrices
• 5. Thermoset Processing
• 6. Composites
• 7. Future Prospects for Thermosets and Composites
• Conclusion
• Glossary
• Index