Polymer Lab Report

Experiment no: 04
Name of the experiment: Processing and Characterization of Fiber

Reinforced Polymer Matrix Composite
Course no: MME476

Group no: 2B
Submitted by,
1511031
1511032
1511033
1511034
1511035
Date of performance: 22.07.2019

Date of submission: 26.08.2019
Objective:
To prepare fiber reinforced polymer composite by hand layup and hot compression molding
technique.
Theory:
A thermosetting polymer, resin, or plastic, often called a thermoset, is a polymer that is irreversibly
hardened by curing from a soft solid or viscous liquid prepolymer or resin. Curing is induced by
heat or suitable radiation and may be promoted by high pressure, or mixing with a catalyst. It
results in chemical reactions that create extensive cross-linking between polymer chains to produce
an infusible and insoluble polymer network. Hand lay-up is an open molding method suitable for
making a wide variety of composites products from very small to very large. Production volume
per mold is low; however, it is feasible to produce substantial production quantities using multiple
molds. Hand lay-up is the simplest composites molding method, offering low cost tooling, simple
processing, and a wide range of part sizes.
A thermoplastic polymer material that becomes pliable or moldable at a certain elevated

temperature and solidifies upon cooling. Most thermoplastics have a high molecular weight. The
polymer chains associate by intermolecular forces, which weaken rapidly with increased
temperature, yielding a viscous liquid. In this state, thermoplastics may be reshaped and are
typically used to produce parts by various polymer processing techniques such as injection
molding, compression molding, calendaring, and extrusion. Compression molding is a common
process used for both thermoplastic and thermoset stock shape materials. Compression molding is
accomplished by placing the plastic material (can be a granular or pelletized form) in a mold cavity
to be formed by heat and pressure. The process is someone similar to making waffles. The heat
and pressure force the materials into all areas of the mold. The heat and pressure cycle of the
process will harden the material and then it can be removed.
Materials Used:
A. Tray, paint brush, bowel, duster, hand gloves. nose musk. Pipette, syringe, roller, scale, digital
weight machine etc.
B. Epoxy resin, polypropylene, jute mat, hardener, silicon spray, plastic sheets etc.
Working Procedure for Thermoset Composite:

Hand lay-up techniques are used to fabricate the unique sandwich panels where resin is manually
applied to jute mat fiber reinforcement using common paint rollers. Rollers are used to remove
air bubbles from the laminate. After cure, assemblies are trimmed to the proper width.
Following steps were carried out for the processing of thermoset composite:
1. Measured its and jute mat`s dimension and weight carefully.
2. Mixed hardener and epoxy resin in the proportion of 10:90. The mixture was stirred properly
so all gas bubbles get eliminated.
3. Placed a transparent plastic sheet on the tray and applied the epoxy hardener mixture
thoroughly, then placed the jute mat over the applied mixture and then again applied another
layer of that mixture on the mat and covered it by another jute mat followed by another layer of
epoxy and a plastic sheet. Then it was properly rolled with a hand roller so to eliminate the
entrapped bubbles.
4. Finally another tray was placed over the system to put pressure.
5. It was then left for a day for curing to take place.
6.Dimensions and weight of the final product was taken carefully.
Working Procedure for Thermoplastic Composite:

1. Cleaned the mould properly then took the measurements of the mould and the jute mat.
2. Applied mould release agent: silicon spray on both part of the mould.
3. Then applied a layer of PP grains and the placed the jute mat over the layer of PP grains, then
again applied a layer of PP grains over the jute mat.
4. Then the other part of the mould is placed over the last PP layer. Then it was placed into the
hot compression machine.
5. It was kept for 15 minutes at 160°C and then raised to 195°C. after reaching 195°C it was
cooled to room temperature. Then the measurement of the final product was taken.
Calculation:
Thermoplastic Composite:
Dimension of the mold: 145x145 mm2
Thickness of the thermoplastic composite product = 3.28 mm
Volume of the thermoplastic composite product = 145 x145 x3.28= 68962 mm3
Weight of the thermoplastic composite product = 60g
Dimension of mat:
a) Length: 145 mm
b) Width: 145 mm
c) Thickness: 0.5 mm
Volume of the mat =145x145x0.5 mm3 =10512.5 mm3
Weight of mat= 25g
Volume of polypropylene = (68962-10512.5) = 58449.5 mm3
Weight of polypropylene = (60-25) = 35g
58449.5
Volume fraction of polypropylene = = 0.85
68962
35
Weight fraction of polypropylene = 60 = 0.58
10512.5
Volume fraction of mat = = 0.152
68962
25
Weight fraction of mat = 60 = 0. 42
Thermoset composite
Dimension of mat:
Length: 250 mm
Width: 190 mm
Thickness: 0.5 mm
Thickness of the thermoset composite product = 2.57 mm
Volume of the mat = 2 x 250x190x0.5 mm3 = 21025 mm3
Volume of the thermoset composite product = 250 x 190 x 2.57 mm3 = 122075 mm3
Volume of the epoxy resin = (122075-21025) mm3 = 101050 mm3
Weight of mat =120 g
Weight of the thermoset composite product = 150 g
Weight of the epoxy resin = 150-120 = 30 g
101050
Volume fraction of epoxy resin = = 0.83
122075
30
Weight fraction of epoxy resin = 150 = 0.2
21025
Volume fraction of mat = = 0.17
122075
120
Weight fraction of mat = 150 = 0.8
Observation:
Thermoplastic:
 The jute mat was not distributed thoroughly rather it displaced to one corner.
 Surface of the product was smooth.
 There was some aggregation of polypropylene in some places which blocked the view of
the jute mat.
 A crack was visible on the corner where reinforcement was absent.
Thermoset:
 As the plastic sheet wasn`t properly removed, the surface seemed rough in some places.
 Air bubbles were visible on the surface.
 The product was harder and stronger than the thermoplastic composite.
 The reinforcement jute mat was visible clearly as the epoxy resin is transparent.

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What materials and processes were used to make the fiber reinforced polymer composites?

What are the differences between thermoplastic and thermoset composites?

Experiment no: 04

Name of the experiment: Processing and Characterization of Fiber

Course no: MME476

Date of performance: 22.07.2019

A thermoplastic polymer material that becomes pliable or moldable at a certain elevated

Working Procedure for Thermoset Composite:

Working Procedure for Thermoplastic Composite:

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