The incorporation of FRP composite technology
into the industrial world is less than a century old. The true age
of plastics emerged just after 1900 with chemists and industrialists
taking bold steps to have plastics (vinyl, polystyrene and plexiglass)
mimic and outdo nature’s own materials. Spurred on by the needs
of electronics, defense and eventually space technologies, researchers
created materials with properties that seem to defy known principles,
like Kevlar stopping bullets. The first known FRP product was a boat
hull manufactured in the mid 1930’s as part of a manufacturing
experiment using a fiberglass fabric and polyester resin laid in a
foam mold. From this somewhat inauspicious beginning, FRP composites
applications have revolutionized entire industries, including aerospace,
marine, electrical, corrosion-resistance and automotive/transportation.
Fiber-reinforced polymer (FRP) composite materials date back to
the early 1940’s in the defense industry, particularly for use
in aerospace and naval applications. The U.S. Air Force and Navy capitalized
on FRP composites high strength-to-weight ratio capability and inherent
resistance to weather and the corrosive effects of salt air and sea.
By 1945, over seven million pounds of fiberglass were being shipped,
primarily for military applications. Soon the benefits of FRP composites,
especially its corrosion resistance capabilities, were communicated
to the public sector. Fiberglass pipe, for instance, was first introduced
in 1948 for what has become one of its widest areas of use within
the corrosion market, the oil industry. FRP composites proved to be
a worthy alternative to other traditional materials even in the high-pressure,
large diameter situations of chemical processing. Besides superior
corrosion resistance, FRP pipe offered both durability and strength
thus eliminating the need for interior linings, exterior coatings,
and/or cathodic protection. Since the early 1950’s, FRP composites
have been (and still are) used extensively for equipment in the chemical
processing, pulp and paper, power, waste treatment, metals refining
and other manufacturing industries. Myriads of products and FRP installations
help build a baseline of proven performance in the field in such products
as chemical plant scrubbers, hoppers, hoods, ducts, fans, stacks,
piping, pumps and pump bases, valve bodies and above-ground as well
as underground tanks for chemicals or gasoline.
The decades after the 40’s brought new, and often times, revolutionary
applications for FRP composites. The same technology that produced
the reinforced plastic hoops required for the Manhattan nuclear project
in World War II, spawned the development of high performance composite
materials for solid rocket motor cases and tanks in 60’s and
70’s. In fact, fiberglass wall tanks were used on the Skylab
orbiting laboratory to provide oxygen for the astronauts. In 1953,
the 1st production Chevrolet Corvette with fiberglass body panels
rolled off the assembly line. Now, high-performance racecars are the
proving ground for technology transfer to passenger vehicles. In the
1960’s, the British and U.S. Navies were simultaneously developing
minesweeper ships as FRP composites are not only superior to other
materials in a harsh marine environment, they are also non-magnetic
in nature. It was also noticed at that time that one of the features
of FRP is the ability of the materials to reduce the radar signature
of the structure, such as a ship or an aircraft. High performance
composites materials have been demonstrated in advanced technology
aircraft such as the F-117 Stealth Fighter and B-2 Bomber. Currently,
FRP composites are being used for space applications and are involved
in several NASA test initiatives.
The marine market was the largest consumer of composite materials
in the 1960’s. In the 1970’s, the automotive market surpassed
marine as the number one market; a position it retains. Composites
have also impacted the electrical transmission market with products
such as pole line hardware, cross-arms, and insulators.
While the majority of the historical and durability data of FRP composite
installations come from the aerospace, marine and corrosion resistance
industries, FRP composites have been used as a construction material
for several decades. FRP composite products were first demonstrated
to reinforce concrete structures in the mid 1950’s. In the 1980’s,
resurgence in interest arose when new developments were launched to
apply FRP reinforcing bars in concrete that required special performance
requirements such as non-magnetic properties or in areas that were
subjected to severe chemical attack.
Composites have evolved since the 1950’s in architectural applications
starting with semi-permanent structures and continuing with restoration
of historic buildings and structural applications. Typical products
developed were domes, shrouds, translucent sheet panels, and exterior
building panels.
During the late 1970’s and early 1980’s, many applications
of composite reinforcing products were demonstrated in Europe and
Asia. In 1986, the world’s first highway bridge using composites
reinforcing tendons was built in Germany. The first all composites
bridge deck was demonstrated in China. The first all composites pedestrian
bridge was installed in 1992 in Aberfeldy, Scotland. In the U.S.,
the first FRP reinforced concrete bridge deck was built in 1996 at
McKinleyville, WV followed by the first all-composite vehicular bridge
deck in Russell, KS. Now, there are hundreds of bridges worldwide
that are utilizing composite technology for civil infrastructure including
internal and external strengthening of structures and bridge deck
replacement.
FRP Composites have impacted and even revolutionized several major
markets. This is just the start. The nine market segments listed here
have to be continually refined as new products are being launched
each year. And new markets, such as blast mitigation (as a part of
Homeland Security) are in forefront for eventual commercialization.
For all of FRP composites strengths, versatility is its greatest asset
creating infinite possible solutions to improve quality, provide safety,
and increase performance.
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FRP composites are no longer
considered "space-age" materials utilized only for stealth
bombers and space shuttles. This versatile material system has become
a part of everyday life. In fact, composites are so widely used and
in such varied of applications, the overall composites market had to
be divided in the following major commercial segments to cover its 1000’s
of products.
Aircraft/Military
Commercial, pleasure and military aircrafts, including components
for aerospace and related applications
Appliance/Business
Composite applications for the household and office including appliances,
power tools, business equipment, etc.
Automotive/Transportation
The largest of the markets, products include parts for automobiles,
trucks, rail and farm applications.
Civil Infrastructure
A relatively new market for composites, these applications include
the repair and replacement of civil infrastructure including buildings,
roads, bridges, piling, etc.
Construction
Includes materials for the building of homes, offices, and architectural
components. Products include swimming pools, bathroom fixtures, wall
panels, roofing, architectural cladding
Consumer
Products include sports and recreational equipment such as golf clubs,
tennis rackets, snowmobiles, mobile campers, furniture, microwave
cookware
Corrosion-Resistant Equipment
Products for chemical-resistant service such as tanks, ducts and hoods,
pumps, fans, grating, chemical processing, pulp & paper, oil &
gas, and water/wastewater treatment markets
Electrical
This encompassing market includes components for both electrical and
electronic applications such as pole line hardware, substation equipment,
microwave antennas, printed wiring boards, etc.
Marine
Products for commercial, pleasure and naval boats and ships.
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