Tests of Pultruded FRP Plank as Formwork and Reinforcement for Concrete Structures
By: Lawrence Bank
Company: University of Wisconsin
Description:
A feasibility study using a pultruded FRP plank as both formwork and tensile reinforcement for concrete slab structures was conducted. This type of reinforced concrete element can be used for rapid construction of concrete members reinforced with non-corrosive FRP materials. The critical structural requirement of this system is to develop composite action between the pultruded plank and the concrete. This depends on developing a satisfactory bond between the smooth surface of the pultruded plank and the concrete. In this study, different surface treatments were applied to the pultruded FRP plank to create a bond with the concrete. Concrete beams of different lengths and depths were fabricated using a commercially available pultruded FRP plank (SafPlank by Strongwell). Two kinds of aggregate, gravel and sand, were bonded to the pultruded FRP plank using a commercially available epoxy system. No additional flexural or shear reinforcement was provided in the beams. One of the beams was used as a control specimen and did not have any aggregate on the FRP plank. The fabricated beams were loaded by patch load to their ultimate capacity. The experimental results were compared to current ACI 318 and ACI 440 code predictions. Depending on the length and depth of the beam, shear or flexural failures occurred which demonstrated satisfactory bond between the FRP plank and the concrete. The cracking behavior of the beams was found to be a function of the type of aggregate used. The gravel attached specimen showed slightly more cracks and slightly smaller width of the cracks compared to the sand attached specimen. The ultimate strengths of the tested specimens showed considerable enhancement compared with the control specimen. It was found that a pultruded FRP plank with aggregate attached has the potential to serve as a stand-alone formwork and reinforcement system for concrete beams and slabs of appropriate dimensions.

Burning Behavior at High Applied Heat Flux Levels: Implications for Determination of Material Properties
By: Patricia Beaulieu
Company: FM Global
Description:
A challenge related to characterizing the fire performance of material systems and how to measure true (scaleable) fire properties of these systems is currently faced by the composites industry as well as the fire engineering industry. The growth in the use of fire models to simulate actual scenarios necessitates that fire engineers have material “property” information that is valid. Understanding materials’ performance at high heat fluxes allows for insight into determination of scaleable properties as well as providing an opportunity for the composites industry to clearly demonstrate superior performance of its materials. This paper presents results from a recent study conducted in the Advanced Flammability Measurements Apparatus (AFM) which is an enhanced bench scale apparatus similar to Fire Propagation Apparatus ASTM E 2058 and Cone Calorimeter ASTM E 1354 to provide more insight into phenomena associated with horizontal ignition and burning. It builds upon previous work presented at Composites 2004 where burning results were preliminary and not yet distilled. This new work builds upon that and presents significant conclusions for burning behavior and its key “property” heat of gasification. This “property” is found to vary with heat flux level (heating rate) and to be different as compared to the value obtained from differential scanning calorimetry. These results will be detailed and discussed in the context of proper use of these values for indexing of materials as well as in fire modeling.

Design of Experiment Study of Cure Reactivities of BMC Material
By: Li Bradshaw
Company: Mar-Bal Incorporated
Description:
Understanding how level of peroxides, inhibitors and temperature affect cure is essential to optimizing formulations and processes for unsaturated polyester systems. Factorial design of experiment is utilized to study these variables. A typical Bulk Molding Compound (BMC) with an isophthalic acid based unsaturated polyester formulation was used in studying cure and flow properties. The formulation is targeted for elevated temperature molding applications. Basic cure properties such as gel time, inflection time, peak temperatures and spiral flow were measured. Effects of peroxides, inhibitors and temperature on cure and spiral flow characteristics are discussed.

Surface Analysis of SMC Panels
By: Bill Carroll
Company: Reichhold, Inc.
Description:
The surface profile of components produced from sheet molding compound (SMC) is often a requirement for specifying the material in many industrial applications, particularly in the automotive industry. Various methods have been used over the years to attempt to quantify the quality or smoothness of molded surfaces. In this paper we will describe the use of the Ondulo method, compare it to classical measurement systems and illustrate the advantages and unique features of the system. Examples will be shown as to how the information from an Ondulo analysis can aid in improving and maximizing the surface and appearance of SMC panels and components.

Exact Equation to Predict the Durability of Composites
By: Antonio Carvalho
Company: Reichhold
Description:
"How to predict the structural life of composites
For full acceptance in infra-structure applications the solutions offered by composite materials must be cost competitive and durable. The first thing that the infra-structure engineers looks at when faced with the choice among a variety of competing materials is cost. If the price is good, the question of durability is next. The composites industry has evolved to the point of being very cost competitive versus the so-called traditional materials. The issue of durability, however, has still not been properly addressed. The many studies and test methods that have been developed by the composites industry over the years, while useful to estimate the structural lifetime, do not provide fully satisfactory answers.
This paper introduces an exact formula to predict the durability of composites under static and cyclic loadings. The derivation of this exact formula is presented in full detail. Also, the exact formula is compared with the current empirical expression used by the AWWA C-950 to predict the lifetime of composite pressure pipes that are used in water transmission."

Service Life of Composites in Industrial Applications
By: Antonio Carvalho
Company: Reichhold
Description:
"Functional life of composites The corrosion barrier of composite structures used in aggressive environments must be replaced at regular intervals. The functional life of such structure is the time interval between the removal and reconstruction of the corrosion barrier. The composites industry does not have a reliable method to predict functional lives that would facilitate the planning and scheduling of plant shutdowns for maintenance. The current test method – ASTM D – 581 – used to assess the chemical resistance of composites and resins in corrosive media cannot be used to predict functional lives. This paper introduces a new test method that generates a regression line linking the loss of laminate thickness with the exposure time. This regression line can be used to predict the functional life of any laminate in any corrosive media. And conversely, it could also be used to design the corrosion barrier for any desired functional life. This new design tool fills a blatant gap in the technology of composites. The new test method proposed in this paper is fundamentally different from the currently used ASTM D – 581 test method. In execution, however, the two methods are very similar."

Manufacturing and Performance Evaluation of Soy-Based Nanocomposites
By: K. Chandrashekhara
Company: University of Missouri - Rolla
Description:
Epoxy-clay nanocomposites were synthesized using a soy-based epoxy resin, which was prepared by the process of transesterfication and epoxidation of regular food grade soybean oil. Nanoclay was dispersed into the soy-based epoxy resin using a high shear mixer and sonication. Tensile testing of the nanocomposites showed that the nanoclay improved the modulus and the strength by 340% and 625%, respectively. Exfoliation of the nanoclay was investigated by X ray diffraction. The influence of the montmorillonite clay upon the curing efficiency of the epoxy-anhydride resin system was studied as a function of the clay concentration using differential scanning calorimetry. Rheological measurements were also conducted to find the suitability of using the soy-based epoxy clay nanocomposites toward common composite manufacturing applications. The soy-based nanocomposites hold great promise as environmentally friendly and low cost materials for structural applications.

Building Code Requirements, Required information for Performance Based Designs, and Fire Modeling of Composite Materials
By: Andrew Coles
Company: Arup
Description:
"Building Code Requirements, Required information for Performance Based designs, and Fire Modeling of Composite Materials.
Although the nature of the building codes in the United States is primarily prescriptive, developers, designers and manufacturers should be cognizant of performance-based options that can alleviate the prescriptive restrictions on the choice of materials. For example, the codes prescribe strict requirements for structural, insulating and decorative building materials. As with concrete floors, steel beams, fiberglass insulation and textile wall coverings, composites must meet prescribed testing criteria before they can be used in a building environment. Sometimes, architecturally desirable building products or materials may not meet the prescriptive testing criteria, even though the material, as proposed, may not be any more hazardous than the permitted material. The criterion is particularly onerous in larger, commercial structures required to be of non-combustible construction. A seldom used clause in the codes permits alternate designs or materials (i.e. deviations from the code prescribed designs or materials) as long as the alternate does not result in an otherwise less safe design. In some cases, alternate approaches, often referred to as Performance Based (PB) designs can be applied by fire engineers to show that an alternate material will not affect the level of fire safety intended by the code. This paper discusses the impact of prescriptive code requirements on the choice of building materials, how the code impacts and restricts the use of composite materials, and how composite materials could be introduced into a building design with the application of performance based design methodology. An economical fire testing program is recommended to material suppliers and composite fabricators so that fire engineers can more readily apply performance-based design tools. Case studies where computational fluid dynamic (CFD) fire modeling was used in a subway train and a train station will be used to illustrate the usefulness of this methodology."

Characterization of Pultruded Polyurethane Composites: Environmental Exposure and Component Assembly Testing
By: Michael Connolly
Company: Huntsman Polyurethanes
Description:
Polyurethane-based composites have become an accepted alternative in the pultrusion industry, especially for high performance applications. Pultruded composites based on two-component polyurethanes are now widely known to exhibit superior strength and toughness compared to traditional pultrusion resins, allowing manufacturers to cost-effectively produce lighter, stronger and more damage tolerant profiles. However, verifying that a particular material meets the physical property requirements for an application is only one step in ensuring that material is fit for the purpose. Evaluation of pultruded profiles in ‘real world’ tests such as long term environmental exposure and performance in secondary processing and assembly operations is critical to ensure component functionality is maintained over its life-cycle. This paper will report on physical property changes due to environmental exposure for pultruded polyurethane (PU), vinyl ester (VE), unsaturated polyester (UPE) and unsaturated polyester-urethane hybrid (UPE-PU) composites. Environmental tests include UV exposure and immersion in water, salt water, hydrocarbon fluids and strong acid and base solutions. In addition, performance of each resin system will be compared in composite assembly methods including screw pull-out, bearing strength and adhesive lap-shear testing.

Effect of Resin Type and Glass Content on Fire Engineering Properties of FRP Composites
By: Nicholas Dembsey
Company: WPI Fire Protection Engineering
Description:
This study is designed to provide the composites industry as well as the fire engineering industry baseline data and engineering "properties" of common FRP systems. Four resin systems and three glass contents will be considered. This matrix of FRP systems has been carefully fabricated and documented so as to provide transparency as to the system compositions. An important and interesting aspect of these FRP systems is that all the resins used are listed by the manufacturers as Class 1 or Class A per ASTM E84. The FRP systems are being evaluated in bench scale modern fire test apparatuses (FPA ASTM E 2058 and AFM, which are both similar to the Cone Calorimeter ASTM E 1354). These apparatuses provide a range of measurements such as heat release rate that can be used to calculate engineering "properties" of these FRP systems. The "properties" then can be used to screen these FRP systems for fire performance. The fire performance criterion to be used is flashover (full room involvement). Modern building codes in general require the fire engineer to design to prevent flashover from occurring. The effect of resin type and glass content will be discussed relative to prevention of flashover for common FRP systems.

Total Organic Content (TOC) in SMC/BMC Molded Parts
By: Frank Doherty
Company: Norac, Inc.
Description:
In the recent history of composites, one issue that has been addressed, and is still being addressed is that of resdual styrene content in the molded part. Cosiderable progress has been made in reducing residual styren and the accompaning problems of odor and/or painting and bonding problems. Whole styrene is a major component of TOC, there are other TOC contributors introduced in the formulation of SMC/BMC molding compounds. To increase the recyclability of SMC/BMC automotive parts, the European auto industry has taken steps to measure and reduce TOC in molded parts. This paper will look at how TOC can be reduced by altering molding parameters and choosing alternative organic peroxide cure initiators. Of equal importance has been the development of a reproducible anallytical procedure for the meassurement of TOC. To date, the US auto industry has not adoptd the European criteria, but if and when it does occur, the development of a TOC protocol is well on it's way.

High UV Resistant Colorfast SMC
By: Bill Dolan
Company: Jet Moulding Compounds, Inc.
Description:
"Unsaturated polyester resin in SMC and BMC systems have been recognized for their susceptibility for weathering stability. When exposed to the outdoor environments, the SMC & BMC compounds will undergo color change, loss of gloss, cracking and other UV-indicated deterioration. For some extreme cases, chalking could be evident within a few months. Jet Moulding Compounds Inc. is a specialized SMC & BMC compound manufacturer of thermoset compounds for various markets. Through our extensive research development over the past several years, a stable UV resistant system has been developed broadening the outdoor use of SMC & BMC thermoset compounds. Through great technical support by Plasticolors, this project investigated the effect on UV testing various pigments, UV additives, various polyester resin bases, fillers, fiberglass and many other additives."

Electrical and Mechanical Properties of Conducive Carbon Polyolefin Composites
By: Ali Farshidfar
Company: SAPCO
Description:
"The electrical conductivity of polymers can be increased by the addition of conductive fillers, including forms of carbon fibers and carbon black . The resulting composites can be used in applications where metals have typically been the materials of choice. The advantages of using these materials include lighter weight, resistance to corrosion, and the ability to be readily adapted to the needs of a specific application. One of the most significant applications for conductive polymer composites are conductive carbon-polymer composite electrodes. As many properties such as conductivity, mechanical integrity, low permeability, electrochemical activity and stability in the electrolytes are required of materials to be used as electrodes, so “ material selection” plays a crucial role in fabricating these materials. In this work it was found that high density polyethylene (HDPE)/ethylene-propylene-diene monomer(EPDM) blend ratio (70/30) has lower percolation threshold and volume resistivity than individually carbon black filled HDPE and EPDM due to”double percolation” effect. Carbon fibers were also added to the polymer-carbon black mixtures to enhance the conductivity and mechanical Properties. The electrical conductivity of composites with different ratios of carbon black (CB) content to carbon fiber (CF) content was studied . The CB content is the main factor to determine the resistivity of the composites filled with CB and CF. Mechanical properties, including tensile strength, elongation at break and impact strength of the conductive composites were evaluated. The results showed that incorporation of CB and CF in the composites will enhance tensile strength, but decrease elongation at break and impact strength of the composites. In mechanical properties, CF content has a greater effect than CB content. From the comparasion of the resistivity and mechanical properties of the composites filled with CB and CF with that of the composites filled with CB only, it is conclude that using CF as a substitute for part of the CB in CB-filled composites can enhance electrical and mechanical properties."

Properties of Structural Sandwich Core Materials: Hand Lay-up vs. Vacuum Infusion Processing
By: Kurt Feichtinger
Company: Alcan Baltek Corporation
Description:
"Vacuum-Assisted Resin Transfer Molding, or "vacuum-infusion," has grown significantly in popularity over the past decade or two in part due to advantages of a significantly reduced environmental footprint, lower weight per unit area, and debatably lower manufactured part cost. Suppliers of reinforcements and resins have undertaken considerable research on the physical properties of “single-skin” composites produced by vacuum-infusion in relation to contact molding. However, little has been presented on similar comparisons for structural sandwich composites. Thus, the objective of this study was to compare the properties of identical laminate builds comprising two plies of 1808 E-glass fabric on each side of nominal ½" (12.5 mm) thick core materials, produced by both vacuum-infusion and hand lay-up processing. Core materials investigated included pre-coated/decay-resistant end-grain balsa, two densities and two suppliers of cross-linked PVC foams, two extruded PET foam variants, an extruded polypropylene honeycomb core, one density of an SAN foam, three densities of polyurethane foam, and a special core comprised of an assembly of low-density polyurethane foam planks filament wound with E-glass rovings, bound on both sides with scrim. All core materials with the exception of the last two types were scrimmed and had either knife-cut or saw-cut kerfs. The polyurethane foam cores were not scrimmed, but instead were double-cut. Characterizations included initial core density, laminated weight per unit area, average thickness, and strength and stiffness for both flexural as well as "flatwise" tensile testing. Significant among the findings of this study were a substantial reduction in overall panel thickness and areal weight, subtle differences in flexural strength, a significantly lower flexural stiffness, slightly greater flatwise tensile strength, and significantly greater flatwise tensile moduli, for vacuum-infusion processing in comparison to hand lay-up."

Optimizing Peroxide Performance for Vacuum Infusion
By: Dennis Fink
Company: Norac, Inc.
Description:
One of the common concerns, perhaps the biggest problem, of modern vacuum infusion processes is dealing with the combined effect of resin gaining viscosity as it starts to gel in the mold cavity. This leads to poor wet out of the gleass and coring material, poorer release of air, and higher infusion pressures. Our studies will show that the proper balance of Monomer, Dimer, and Trimer ratios of MEKP initiator can have a positive effect on all three of these aspects.

Low Velocity Impact and Damage Behavior of Kevlar Bonded M30/8551 Composites Fabricated Using P-WaveTM NIR Irradiation
By: Bazle Gama
Company: University of Delaware Center for Composite Materials
Description:
"Quasi-static punch shear tests and low velocity impact tests are conducted on M30/8551 carbon/epoxy Baseline laminates, thermoplastic polyurethane (TPU, KUB310) bonded Kevlar/M30/8551, Ionomer (KUB100) bonded Kevlar/M30/8551, and Epoxy (Hysol® EA 9321) bonded Kevlar/M30/8551 composite specimens. The TPU and Ionomer bonded specimens are fabricated using Kubota Research Associates, Inc.’s P-WaveTM near infrared (NIR) irradiation and patent pending pseudo coating technique to avoid thermal degradation of the baseline composites. Impact experiments in the velocity range 2.5 to 4 m/s show that, the Baseline composite specimens catastrophically fail in the rear face of impact, while the TPU, ionomer, and epoxy bonded Kevlar specimens contains the back/rear face fracture inside the Kevlar skin. The TPU bonded specimens are found to perforate at both 80J and 93J impact energies and the average perforation energy is found to be 77.1J, which is 29% higher than the baseline (60J). The Ionomer bonded specimens are found to perforate at 93J impact energy and the energy absorbed at perforation is found to be 83.5J, which is 39% higher than baseline. The Epoxy bonded specimens are found to perforate at 60J impact energy and the perforation energy is found to be 56.48J, which is 6% less than the baseline. Details on the bonding process and impact results will be presented."

The Importance of Color in New Composite Applications
By: Harry George
Company: Bayer MaterialScience LLC.
Description:
Aesthetics, in particular color and finish, of end use OEM applications are a major driving force in determining the manufacturing method of finished products. OEM demands for cost effective, higher aesthetic quality in finished products drives new technology development and innovation in the industry. Processors who embrace innovations in the manufacturing methods and techniques related to aesthetics are expanding their businesses. Case studies will be presented in support of this hypothesis.

Metal Matrix Composite Filament Winding
By: Brian Gordon
Company: Touchstone Research Laboratory, Ltd.
Description:
Touchstone Research Laboratory is developing a metal matrix composite (MMC) filament winding technology to meet the needs of advanced, high temperature composites applications. This paper summarizes the results of 4-inch diameter MMC cylinders tested in tension, torsion, and internal pressure (hydrostatic burst). The results showed a generally linear lamina response in longitudinal tension and a significantly non-linear lamina response in transverse tension and shear. The hydrostatic burst tests resulted in a translation efficiency of up to 80% in uniaxial testing of hoop-only cylinders, and 60% in biaxial testing of cylinders made with both hoop and helical plies. Improvements to the incoming fiber tows and processing modifications will be pursued to raise these translation efficiencies. This testing will lead to the development and refinement of predictive models that can be used for designing MMC pressure vessels and storage tanks.

VARTM Processing Applied to M939 Fender Fabrication
By: Dana Grow
Company: Sioux Manufacturing Corporation
Description:
Vacuum Assisted Resin Transfer Molding (VARTM) has the potential to lower production costs through low-cost tooling approaches, low resin and reinforcement costs, and reduced processing time. An examination of a number of these factors will be illustrated using the example of the M939 fender. This part has been selected for possible transition from metal to composite by the US Army, due both to enhanced physical properties of the composites compared to sheet metal, and potential reduced fabrication costs. Adequate stiffness is key to the performance of the fender in the field, and this property has been measured on actual parts and exhibited good agreement with finite element simulations.

Analytical Fire Model for Composite Materials in the Building Industry
By: Jason Huczek
Company: Southwest Research Institute (SwRI)
Description:
The objective of this paper is to discuss test results and developed analytical models that relate small-scale fire test data to larger-scale fire test performance. Results will be presented for a glassfiber-reinforced plastic material, when tested in accordance with ASTM E1354 (Cone Calorimeter), ASTM E1623 (ICAL Apparatus), ASTM E84 (Steiner Tunnel), ISO 9705 (Room Corner) and EN ISO 13823 (SBI). The data will be compared with literature data for similar materials and SwRI-developed correlations and models will be presented that relate the performance of the material in the cone calorimeter to the performance of the material in the other larger-scale test apparatuses.

Investigation of Infrared Reflective Pigmentation Technologies for Coatings and Composite Applications
By: David Hyde
Company: Plasticolors, Inc.
Description:
Recent advances in pigmentation technology have allowed the formulator to achieve a greater infrared reflectivity versus traditional pigmentation technologies in functional coatings, while maintaining the appropriate light absorption in the visible spectrum to impart color. The ability of functional infrared reflective coating systems to lower heat build-up results in reduced thermal warpage, reduced thermal cycling degradation, lower energy costs related to cooling, and improved comfort and functionality of dark color exterior objects such as park benches, hand railings, and even polymer concrete. This paper will impart knowledge of infrared pigmentation technology to the reader, and explore potential new applications of infrared reflective pigmentation technology in composites.

Behavior of Three Dimensionally Woven Glass Fiber Reinforced Polymeric Bridge Deck
By: Charles Johnson
Company: North Carolina State University
Description:
In the past two decades, glass fiber reinforced polymer (GFRP) bridge decks have been considered as an alternative to conventional steel and concrete bridge decking. The study presented in this paper investigated the behavior of a new and innovative 3-D woven GFRP bridge deck. The proposed deck consisted of two skins of E-glass fabric and vertical webs to act as flexural members supported by the girders. Each skin consisted of two orthogonal fabrics stitched together by fibers in the perpendicular direction to form a 3-D GFRP material for the entire cross section. Balsa cores were inserted to maintain the configuration of the cross section during the vacuum infusion process using epoxy resin. This paper focused on the behavior of two types of decks: GFRP bridge deck and GFRP-concrete hybrid deck. The fundamental material characteristics of the 3-D woven GFRP materials used, including the tension flexure and shear are presented. The limit state behaviors of the two decks are discussed. A comparison of the behavior of panels infused with vinyl ester and epoxy are presented. The paper discusses also the various types of shear connectors used to achieve the composite action between the GFRP cross section and the top concrete layer. Use of the 3-D woven material eliminates the delamination failure observed for some of the current GFRP bridge decks.

High Temperature Durability of CFRP Laminated RC Beams
By: Damian Kachlakev
Company: California Polytechnic State Univesity
Description:
In order for Fiber Reinforced Polymers (FRP) to be fully accepted as a reliable retrofit option, extensive studies need to be carried out to determine their durability at elevated temperatures. Despite the material’s growing popularity and increasing use, there has been very little research done on the materials resistance to heat. A unique study is being conducted into the durability of steel reinforced concrete beams externally reinforced with FRP laminates at elevated temperatures. Scaled CFRP laminated concrete beams are being loaded while subjected to thermal environments above the resin's glass transition temperature. The study consists of 18 identical flexurally-reinforced beams proof tested at 20%, 40%, and 60% of the ultimate service load while keeping the temperatures constant at 170oF, 300oF, and 500oF. A newly developed strain gage specifically designed for integration into FRP laminates from Hottinger Baldwin Measurement was used to measure the performance of the concrete and the FRP reinforcement. During the laminate application process, these strain gages were easily embedded between CFRP layers and between the concrete and composite reinforcement. Rigid pins normal to the gage plane, allow for simple electrical circuit completion outside of the cured composite without disturbing its mechanical properties. Strains were recorded in the composite and on the concrete independently, allowing for better characterization of the FRP reinforced concrete member. Stress-strain relationships are used to investigate bond degradation mechanisms, creep characteristics, and deflection restraint criteria. The experimental results are used to create a model to predict beam functionality during and after structural fires.

Durability Based Design of FRP Jackets for Seismic Retrofit
By: Vistasp Karbhari
Company: University of California San Diego
Description:
This paper provides results of an investigation aimed at assessing the effect of deterioration over time, at the materials level, on the effectiveness of FRP jackets used for seismic retrofit. Three different systems are investigated and results of accelerated testing are used to provide predictive equations for long-term performance of the material, which are then used to analyze effectiveness at the level of seismic retrofit through four specific cases. The effect of deterioration is expressed, for ease in comparison, to an increase in the required thickness of the jacket with expected service-life. The use of the proposed predictive methodology for materials durability combined with the analytical tools for design of FRP jacket thickness are shown to not only enable a better assessment of required jacket thickness but can also enable assessment of the dominant mechanism controlling selection of thickness which can change with time of exposure.

Coating Development and Plant Trials for Powder Priming of SMC Panels
By: Hamid Kia
Company: GM Research Lab
Description:
Based on the newly discovered powder primer failure mechanism, a joint project was undertaken by GM R&D, Meridian, AOC, and Ashland with the goal of developing powder primer capable class A SMC materials. To that end, more than 40 SMC formulations were prepared and molded into panels for powder primer application readiness. The panels were evaluated for shrinkage, surface profile, moisture absorption, and powder application. Based on these results, four of the SMC formulations were selected for plant trials. The panels molded with the selected SMC materials were sent through the ELPO and powder process of a GM vehicle production plant. The time elapse between the ELPO oven and the start of powder was about 2 hours in one trial, and about 96 hours in another trial. Based on the observed results, it was concluded that the selected final four SMC formulations do not show powder primer popping due to air outgassing, and their moisture absorption is low enough to allow powder priming when there is no line stoppage. It was also noted that, in case of an extended line stoppage and subsequent moisture uptake by SMC panels, the conventional conductive coatings cannot slow down moisture outgassing. Therefore, there is a need to develop a new generation of conductive coatings, which can further slow down moisture penetration into the powder primer. Such experimental conductive coating was developed. However, the performance tests showed that it fails to meet minimum requirements for adhesion. Therefore, the coating formulation was modified through a series of iterations and a final formulation was arrived at. The modified version shows excellent adhesion to all substrates and passes all adhesion tests.

Primary Composite Structures, A Very Large Conference Hall Roof: A Case Study
By: Suhas Kolhatkar
Company: Composite Designs & Technology
Description:
The paper presents a case study of a very large, long span roof structure developed for a Conference hall & Library Building at Bahrain. The roof comprised of five vaults as primary structural composite elements. Each vault has a length of 50m with 7m further cantile-vered overhang. The front Face is of 16m width by 9.25m rise. The rear face is of 8m width by 6m rise. Each vault comprised of six panels, joined together by flange bolted connections. Panels were manufac¬tured in rein-forced concrete moulds. Special CAD designed CNC cut timber templates were used to set up the panel profile in the mould. Manufacturing was done under strict quality procedures. Roof structure of this size in conventional materials like steel or concrete would have imposed very high dead weight on the building structure and the foot-ing. Actual weight of one FRP composite vault as¬sembly is about 30 tones. A similar concrete or steel structure would have been 30 to 50% heavier. The project location is on a water¬front. The Instal¬lation is at an elevation of 28 m above ground level. Wind loads due to gust of 120 kmph and a temperature variation of 150 to 500 C were considered. The FRP Roofing project programme of conceptual design, detailed engineering, tooling, manu-facturing, assembly and installation at site was com-pleted within 16 months.

New Laser Surface Analyzer for Class A Compression Molded Products
By: Francis Krantz
Company: Ashland Inc.
Description:
ALSATM, the Advanced Laser Surface Analyzer is the result of continuing development of surface smoothness analysis utilizing reflected laser lines to evaluate the surface smoothness of a part or panel. With the aging of the LORIATM surface analyzer system obsolescing the equipment, the need for a replacement using current technology was seen. The ALSA surface analyzer system uses a current computer, diode laser, solid state laser line control devices, a Charge Coupled Device (CCD) for image capturing, and a “Windows”TM style environment for the software creating improvements in resolution, speed and ease of use. These improvements were achieved while maintaining an excellent correlation with the surface waviness numbers generated by the LORIA, TM the current standard for measuring long term surface waviness. The Gage Repeatability & Reliability (GR&R) and Correlation studies to validate the system were run utilizing 12 panels and 3 operators. The long term surface waviness of the panels ranged from flat black glass to structural SMC with a wide range of surface waviness in between. Orange Peel is another aspect of surface quality that can be measured by this system. The values calculated were bases on the area under the intensity curve of the line and were confirmed to correlate to a standard set of DuPont TM orange peel standards. The DOI value has been recalculated using the slope of the intensity curve and the width of the line to correlate to a visual image analysis procedure. The new system will give a DOI totally independent of the current system and not a function of orange peel. The new “Windows” TM based software is more user friendly than before and allow the creation and saving of summary data from a series of panels.

A New Amine Promoter for Low-Temperature Cure of MEKP Initiated UPR Systems
By: Wenfeng Kuang
Company: Albemarle Corporation
Description:
A new tertiary amine promoter was developed for free radical curing systems which use MEKP as initiator. A comparison of this amine with DMA and DMPT was conducted in unsaturated polyester/vinyl ester system at and/or below room temperature. The results showed that this amine has higher reactivity than DMA and DMPT, especially below room temperature. By using this amine, it is possible to significantly reduce the usage of cobalt salt, thus reduce the color and toxicity of the final products.

Color and Appearance of Composites: The Future of Instrumental Measurement
By: Ann Laidlaw
Company: X-Rite
Description:
Instrumental practices for the assessment of color and appearance have been in place for many years. Manufacturers use handheld and benchtop spectrophotometers, measuring samples both in contact and non-contact configurations. Users compare colorimetric data from these measurements to visual assessments performed in lightbooths, controlled harmony rooms, and in front of the HR manager’s window. In addition, we may soemtimes use image data to assess the color or appearance of samples. These colors and images may be displayed on web sites, in soft catalogs, or anywhere else, and browsing users assume they are faithful renditions of the actual item. This presentation will review current tools and solutions for assessing color and appearance of composite materials. The paper will also outline projected future developments and needs for rigorous, critical assessment.

Characteristics of Vinyl Ester Laminates Suitable for Chimney Liner Applications After High Temperature Thermal Stress
By: Scott A. Lane
Company: AOC
Description:
Chimney liner laminates made from high performance thermosetting vinyl ester resins need to survive brief high temperature excursions during non-typical plant operations. A test vehicle was developed to characterize the performance of chimney liner laminates made from different vinyl ester resins after a simulated thermal cycle typical of these upset conditions. Differences in appearance, mechanical, and thermal properties are observed and correlate to specific resin chemistry. Vinyl esters are recommended for these application based on the high level of property retention.

Overcoming Vitrification of Polyester Solid Surface Resin for the Kitchen Environment Using Postcure
By: Kenneth Lipovsky
Company: Reichhold
Description:
"In order to become the product of choice it is critical to make sure the part is completely cured. The only way to be sure is to post cure the parts. Recommendations were being made that post cure will happen over time or parts should be placed in an oven at temperatures from 150°F to 250°F for anywhere from 2 hours to 24 hours. Nothing conclusive was ever published for solid surface. This paper will present the data supporting the recommended post cure temperature and amount of time necessary to generate maximum physical properties and show what happens if either temperature or time are extended."

Robotic UV Curing for Resins and Gel Coats
By: Paul Mills
Company: UV Robotics
Description:
"UV curing of composite materials is of growinginterest, driven by economic and environmental concerns.
But since UV curing requires direct line-of-sight to all work surfaces, large, complex shapes present unique challenges for UV.
Until now the prevailing method of curing large parts has been to utilize a large number of individual fixed lamps. This is costly and still may not achieve full cure for very complex shapes.
new developments in robotic UV curing equipment and techniques may now enable manufacturers to realize the potnetial of UV curing ina cost-effective and robust manner.
This paper will demonstrate the effectiveness of robotic UV curing for composite resin and gel coat operations. The technical performance and economics for several actual composite projects lfor automotive and industrial applications will be examined.
Contributors to this paper include IST-Metz, Sunrez Corporation and Interplastic. IST Metz is a member of the National Composites Center in Kettering, OH."

Property Retention Studies of Tough Hybrid Urethane Resin Systems
By: Hildeberto Nava
Company: Reichhold, Inc.
Description:
This paper describes the development of high strength resin alternatives to traditional resins predominantly used in the pultrusion process. A study was initiated to investigate the inherent advantages that these new urethane acrylates and hybrid urethane resin systems exhibit over unsaturated polyester and vinyl ester resins systems. Comparative mechanical properties of pultruded substrates based in these various resins were investigated. Corrosion studies on different environments were done for up to 10,000 hrs of exposure. Results on these studies will be presented.

Development of Blush Resistance Gelcoat for Marine Application
By: Ranjit Pachha
Company: Valspar Composites
Description:
"Development of Blush resistance Gelcoat for Marine Application Boat builders have been restricted to white or pastel boats for underwater application due to the blushing of dark colored gel coat. Blushing of the dark colored gel coat is due to the absorption of moisture by the resin, extender and pigments used in conventional gel coat. Since blush resistance gel coats are not commercially available, the choice of hull colors has been restricted to white or pastel. The choice of deck colors has not been restricted, as they are not exposed to water. However, a dark colored gel coat used for above water application has a tendency to blush when the boat is shrink wrapped for storage and transportation. This is due to the condensation of moisture trapped between the shrink-wrap and the gel coat which superheats and causes blushing. Hence, there was a need to develop a gel coat, which does not blush in color or exposure to water. A low VOC gelcoat has been developed using a combination of resins and pigments which has resistance to blushing on exposure to water. The gel coat panels, when exposed to 185F water for 200hrs, give a color change of less than 0.5 Delta E compared to up to 6.0 Delta E with conventional gel coat. Using the newly developed gel coat it will now be possible to make colored hulls without bottom paint, that will retain a blush resistance of less than 0.5 Delta."

Effect of Filler and Void to the Shear Properties of Pultruded Composites
By: Jin Park
Company: Minnesota State University
Description:
This study presents the results of an analytical investigation aimed at examining the mechanical behavior of fiber-reinforced pultruded composites containing nonhomogeneous constituents such as fine clay fillers under shear loading. Analytical formulae that account for the presence of inhomogeneities in the matrix materials were developed for estimating the extensional and in-plane shear moduli, and Poisson¡¯s ratio. The analytical results were compared with the properties obtained from experiments. For the experiments, the pultruded composites containing clay fillers and voids as well as E-glass fibers and vinylester resin were selected, analyzed and tested under shear loading. The effects of presence of constituents on the mechanical properties of matrix materials were also investigated based on the obtained volume fraction of their constituents.

Soy-Based Polyurethane Solutions for Composite Applications
By: Munjal Patel
Company: Urethane Soy Systems Co.
Description:
"Increasingly stringent environmental concerns with composite processing are paving the way for new technology to replace more predominant VOC generating technology such as unsaturated polyester and vinyl ester resins. Now composite manufacturers are presented with soy-based polyurethane resins for use in their respecting applications. Soy-based polyurethane resin offers various benefits, such as improved properties and processing, faster production, and reduced VOC emissions.
Soy-based polyurethane resins can replace traditional resins in composite market segments such as Hand/Spray lay-up, RTM, and Filament Winding. One composite market segment wherein soy-based technology has been used is that of pultrusion. Benefits and a brief discussion regarding lessons learned in pultrusion processing will be discussed further."

Polypropylene Based Novel Flame Retardant Nanocomposite Compositions
By: Prabir Patra
Company: University of Massachusetts Dartmouth
Description:
"Nanoparticles, such as clay and silica have been proven to be effective flame retardants for many commodity plastics and polymers. The past research attributed the flame retardant action of nanoparticles to their physical mode of action in condensed phase by forming protective char layer on top of burning polymer. In this research we are trying to explore chemical mode of flame retardant action of calcium carbonate nanoparticles (CC) along with ammonium polyphosphate (APP) on burning of polypropylene.These two additives present in polymer during fire reacted with each other to produce inert gasses and reduced the burning rate of polymer by 40%. We prepared several polypropylene/ CC/ APP nanocomposites with varying loadings of additives by melt mixing method. In each nanocomposite the weight ratio of APP: CC was kept 2:1 because of stoichiometry of the reaction between APP and CC. We had studied the effect of those two additives on flame spread rate of polypropylene films using standard horizontal flame spread test and observed reduction in burning rate without appreciable char formation. At higher % loading of additives there was char formation at the flame front, which further reduced the burning rate of polypropylene significantly. TGA carried out on the mixture of CaCO3 and APP showed that calcium carbonate nanoparticles react with APP prior to the degradation of phosphate chains. TGA-FTIR studies were carried out on nanocomposite samples and powder mixture of two additives to confirm evolution of ammonia and carbon dioxide due to interaction between the additives. X-ray diffraction of chars obtained after burning the nanocomposite films showed definite crystal pattern and peaks corresponding to that of calcium polyphosphate. These studies confirmed that the two additives react with each other with evolution of inert gasses and cause reduction in flammability of polypropylene. Further study of these two additives on ignition time and heat release rate of polypropylene in cone calorimeter is in progress."

Using ASTM Method C297, Flatwise Tensile Strength, as an Indicator of Resin Acrylic-Bonding-Potential for Tub and Shower Laminates
By: Greg Pattison
Company: Reichhold, Inc.
Description:
Determining a resin’s bonding potential to an acrylic or ABS substrate is critical to a resin manufacturer that supplies the tub and shower industry. Although tub and shower manufacturers have different procedures for testing bonding, these tests are not standardized and the results are largely open to interpretation. ASTM Method C297 is a valuable tool as it is standardized, repeatable, and gives quantifiable data. This paper covers the method in detail, how to apply the method to tub and shower laminates, and why the data can be helpful in predicting a how a resin will perform under real production conditions.

Liquid Molding of Fabric Reinforced Thermoplastic Composites
By: Selvum Pillay
Company: University of Alabama at Birmingham
Description:
The high melt viscosity and short processing window of thermoplastics, precludes the use of liquid molding techniques of continuous fiber reinforced thermoplastic composites. The current research addresses the processing parameters, methodology, and limitations of vacuum assisted resin transfer molding (VARTM) of carbon fabric-reinforced, thermoplastic polyamide 6 (PA6). The material used is casting grade PA6. The process developed for using VARTM to produce carbon fabric-reinforced PA6 composites is explained in detail. Studies on infusion temperature, fiber weight fraction, crystallinity, degree of conversion from monomer to polymer are presented. Tensile, flexural, short beam shear strength (SBSS), and low-velocity impact test results are presented and compared to an equivalent thermoset matrix composite.

Alternative FRP Dowel Joint Reinforcement
By: Max Porter
Company: Iowa State Univ.
Description:
Alternative materials from the conventional steel dowels have been investigated for joints as reinforcement to carry the shear forces across the opening. Among these alternative materials, fiber reinforced polymer (FRP) has been given considerable attention. FRP is considered a high candidate to replace steel in those areas where corrosion is of concern. The FRP allows for the slip that is needed but provides for a non-corrosive dowel bar. Alternative dowel bars for joints have been undergoing investigation at Iowa State University (ISU). The alternatives include size, shape and material parameter changes from the conventional 1.5-in. diameter, 18-in. long steel dowels currently employed in joints of pavements, bridge approaches and other locations where load transfer is needed but longitudinal movement must be accommodated. In addition to alternative materials that have been investigated, alternative shapes have been tested and placed in field applications in research projects conducted at ISU. Elliptical, hollow, and other shapes have been tested in the Structural Engineering Laboratory. The tests include elemental behavioral parameter tests, and full-scale pavement slabs subjected to up to 10 million cycles of load. This paper will focus on the structural behavior and field applications of these alternative dowel bars and shapes utilized in conventional joints of a small gap. Results of the tests and field applications will be presented.

Framed Single Skin Laminate Transoms
By: Ron Reichard
Company: Structural Composites, Inc.
Description:
Outboard motors mount to the transom of a boat using “C” type clamps. These motors require a transom to be approximately 2 inches thick to accommodate the mount. This type of transom is still the most common style today. Modern outboard motors are bolted to the transom, thus the requirement for a thick transom is no longer appropriate. This paper compares a traditional fiberglass over plywood transom to a framed single skin transom design. Both designs were analyzed using the finite element method to determine deflections and ply-by-ply stresses for identical load cases. The framed single skin transom has significantly lower deflections and stresses than the GRP plywood transom. It also weighs less, has a lower material cost, and requires less labor to build.

Material Properties of Innovative 3-D Sandwich Panels
By: Engin Murat Reis
Company: North Carolina State University
Description:
This paper presents an innovative 3-D fiber reinforced polymer, (FRP), panels designed to overcome delamination problems typically encountered in traditional sandwich panels. The sandwich panels consist of GFRP laminates and foam core. The panel consists of GFRP plates at the top and bottom connected together with through-thickness fibers to achieve the composite action. The use of the through-thickness fibers increases the out of plane properties of the panel, delays delamination-type failures, allows low cost manufacturing and ensures full utilization of the material strength. The fundamental material characteristics of the panel in tension, compression, flexure and shear are critical for the use and structural design of these panels. This paper summarizes the findings of an extensive experimental program to determine the various parameters affect the material characteristics of these sandwich panels. The influences of the panel thickness, through thickness fiber configuration and density, and other parameters on the tension, flexure and shear behavior of the panels are discussed.

Flame Retardant Performance of Halogen Free, Alumina Trihydrate Based Bulk Molding Compound
By: Gary Rex
Company: J. M. Huber Corp.
Description:
A BMC system depending primarily on Alumina trihydrate (ATH) for flame retardance is shown to give reductions in the volume and opacity of smoke, and heat release rate as compared to a BMC that is highly flame retarded with a brominated compound. In order to achieve this performance high loading levels of ATH were used. High ATH loading levels give a high viscosity which can give processing problems for compounders. In order to minimize viscosity the ATH based BMC formula was optimized via the particle packing technique introduced in a paper, “Rheological Study of Particle Packing in Unsaturated Polyester Resin Loaded with Alumina Trihydrate”, and was presented at ACMA’s Composites 2005.

Improvement in Preform Binder Technology
By: Kevin Richardson
Company: PPG Industries
Description:
Directed Fiber Preforms are a cost effective method for reinforcing Liquid Composite Moldings. In this process, glass fibers are chopped and formed on a screen to the shape of the part to be molded. A binder is necessary to hold the fibers in place for transfer into the mold and prevent displacement during molding. Historically, binders have been adhesives in either liquid or solid form. This paper will discuss the requirements of an ideal preform binder and compare the pro’s and con’s of the various forms. A novel improvement on solid binder will be presented and discussed.

Thermal Conductivity of FyreRoc Systems
By: John Robinson
Company: Goodrich
Description:
Inorganic composites are used in many applications utilizing the material’s high temperature properties. In most of these applications metal and/or a high temperature insulation is being displaced by the inorganic composite system for a variety of reasons ranging from weight to thermal behavior. The insulating properties of the inorganic composite and the capability of building insulating constructions is one of the important characteristics allowing them to compete against the presently available high temperature systems. To demonstrate the advantage of inorganic composite as an insulation system requires being able to measure the thermal conductivity at elevated temperatures for various laminates and sandwich constructions. These thermal conductivity values will then allow for the engineering of the cold side temperatures and thus optimization of thickness and weight for applications such as bulkheads, engine compartments and firewalls. This paper will report thermal conductivity data on the various constructions and laminates along with retention of strength for these systems after high temperature exposures. Discussion of these results and how they compare with present systems will also be included.

Resin Choices for Cured-In-Place Pipe (CIPP) Applications
By: Jerrod Rose
Company: Reichhold, Inc.
Description:
Developed in the 1970's, sewer pipe rehabilitation by curing a resin-impregnated tube within the host pipe has grown in acceptance and usage the world over. This paper will discuss the important parameters and characteristics associated with resin selection and how resin chemistry affects selection. Each rehabilitation project has its own individual requirements and there are both chemical-resistance and mechanical performance considerations that must be taken into account during the design of the liner. Finally, this paper will compare the different resin thickening technologies used to overcome the most commonly encountered problems of sewer pipe rehabilitation such as inflow and infiltration (I/I) and resin migration during inversion and curing.

Effects of Methyl Ethyl Ketone on the Performance of Cast Polymers
By: Louis Ross
Company: Interplastic
Description:
This paper looks at the effect of varying levels of Methyl Ethyl Ketone Peroxide cure initiator on the performance of cast polymer resins. Resin and initiator suppliers routinely recommended initiator levels of 0.75 – 2.5% based on resin. Resin users frequently reject these recommendations when faced with shop temperatures that cause the resin to react too fast or too slow. What are the adverse effects on resins cured with initiator levels outside the recommended levels? Physical properties, extent of cure, and degree of yellowing were measured on castings of a standard cultured marble resin cured with initiator levels ranging from 0.3% to 5.0%. The results clearly show the impact of deviating from the recommended range.

Tough, Low Mass SMC Development for Transportation Applications
By: Rob Seats
Company: Ashland Inc.
Description:
The need for low mass composites in the transportation industry has intensified as OEM’s have looked for ways to reduce vehicle weight in the face of rising oil prices, increasing regulation, and political unrest in the major oil producing countries. Low mass SMC is not a new concept and has been practiced in the industry for several years. However, the limitations of traditional low mass technology have restricted its use to specific applications. The combination of properties to produce low mass Class A SMC without glass microspheres while maintaining the required mechanical and physical properties has not been available. With the introduction of tough SMC technologies in the last few years, molders as well as OEM’s are demanding this technology for future applications to benefit from the performance advantages they bring. This paper will report on recent developments in tough, low mass Class A SMC that achieve a specific gravity of 1.6 and are more robust to molding conditions and exhibit lower water absorption properties than previous developments. Technology and properties of tough, low mass structural SMC with a specific gravity of 1.15 and 1.5 will also be discussed with emphasis on improved mechanical properties as compared to traditional low mass SMC.

A Novel Non-Halogenated Flame Retardant for Composite Materials
By: Aaron Small
Company: Luna Innovations
Description:
Flame retardants, such as inorganic fillers or halogenated resins, are incorporated into composites either as additives or reactive materials. In order to improve processability and mechanical properties, as well as reduce smoke toxicity, a method is being developed to introduce highly effective, inexpensive flame retardant materials into thermoset resins. Superabsorbent polymers (SAP) can be loaded with inexpensive inorganic phosphates as the flame retardant component in composite systems. The resulting SAP flame retardants dramatically improved flame exposure when blended with common matrix resins (epoxy, unsaturated polyester and vinyl ester resins) at relatively low levels with very minimal off-gassing of toxic compounds during combustion.

A New Structural Application for Composite Materials
By: Robert Spaans
Company: Comfort Line
Description:
A new structural application for composite materials in home renovation is introduced. This system, principally made of pultruded lineals combined with molded plastic components leverages multiple strengths of composites. The stiffness, strength, complex shapes, thermal efficiency, and finish options available from composites combine to make a beautiful home enhancement that is higher performing and cost competitive with other material systems. The article will contrast the composite solution with the current state of the art in traditional materials. The development of the product, from design to testing to final installation will be detailed. Some description of material structure and processing methods will be included. (Note to reviewers: at time of submission of the final draft, I will be at liberty to reveal the specific application. The customer is very sensitive about revealing the exact nature of the product until launch in June. As is appropriate for the ACMA audience, the article will focus on the technical details of the product, and will not be a marketing pitch.)

Structural Applications of Long Fiber Thermoplastic Composites
By: Uday Vaidya
Company: UAB School of Engineering
Description:
Successful design, manufacturing, and analysis of Long Fiber Thermoplastics (LFTs) part is presented. Detailed case study of a LFT access door manufactured by extrusion compresson molding for a battery box compartment of a mass transit bus is described.

Some Effects of Mineral Fillers on the Electrical Characteristics of Pultruded Composites
By: James (Jim) Vaughan
Company: University of Mississippi
Description:
Several studies in the research literature discuss the effects of mineral fillers on the mechanical properties of pultruded composites; however, there are fewer studies that discuss the effects on dielectric/electrical properties. This paper will discuss some effects of mineral fillers on the dielectric/electrical properties of pultruded composites, especially at gigahertz frequencies. Mineral fillers including various kaolin clays, aluminum trihydrates (ATH), and calcium carbonate were pultruded using standard resin system formulations and methods typical of the pultrusion industry. Experiments were arranged so as to determine the effects of the different fillers on the electrical properties using different resins, different glass reinforcements, and different amounts of filler since each of these has been mentioned in the literature as a possible influence on the electrical properties of composites. Results show that there are differences in the electrical response in the pultruded composites examined and that both electrical and mechanical property data should be considered when selecting a pultruded system.

Unsaturated Polyester Urethane Hybrid Technology
By: Ron Verleg
Company: DSM Composite Resins
Description:
Unsaturated polyester urethane hybrid technology is relative new group of thermosetting materials in the advanced composite world. The technology is based on combining the chemistry, processing and properties of two thermosets, unsaturated polyester resins and polyurethanes. Products based on hybrids combine the stiffness and thermostability of UP resins and the toughness and flexibility of PUs. Having two curing chemistries, production speed can be adjusted from slow curing to high reacting systems. Moreover the combination of technologies allow hybrid to be processed via PU application techniques, like casting, resin injection molding and foaming - and by UP technoloqies, like hand lay up, spray up, filament winding, resin transfer molding, vacuum injection and pultrusion. Recent studies have revealed an additional, remarkable property of the hybrid system, in that they show fiber/matrix interface properties superior to other thermosetting material. Regardless of the type of fiber (glass, carbon or basalt) the interlaminar shear performance of unidirectional fiber reinforced hybrid rods is at least equal to epoxy based alternatives The good fiber/matrix adhesion performance of hybrids is also supported with the high resistance against hydrolysis of the interface. The combination of speed of production and composite properties opens the opportunities in market segments, like automotive and aviation. DSM Composite Resins has developed a grade of hybrid resin, suited to RTM processing. It is a low viscous two-component system consisting of an A-side based on UP resin and polymeric isocyanate. Another interesting aspect of UPUH is reduction in total cost of the production of an advanced composite part. After production of a fiber-reinforced product based on unsaturated polyester urethane hybrid, it immediately has its structural integrity. When a higher temperature resistance is required, the part does not loose its integrity during the heat treatment. Moreover the glass transition value of the thin composite part increases simultaneously with the heating ramp of the heat treatment schedule. The features of unsaturated polyester urethane hybrid technology allow engineers to manufacture advanced composites in a fast way without compromises the performance. Currently advanced composites are based on epoxy resins. In automotive and aviation industry epoxy based composites are gaining more and more interest for weight saving reasons and freedom in design aspects. Major drawback of epoxy resin is the low reactivity behaviour in RTM that bottlenecks the use of advanced composites on large amounts production. Hybrid resins give a solution to the poor reactivity behaviour without loosing the advanced composite characteristics. This paper will discuss the unsaturated polyester polyurethane hybrid technology, its performance in advanced composites, the processing in injection applications and compares the performance against epoxy resins.

BMC – Taking Automotive Composites to a New Dimension
By: Brett Weber
Company: BMC Inc.
Description:
BMC (DMC, Duroplast) has long been used in automotive applications because of the excellent mechanical properties, creep and thermal resistance. Components such as headlamp reflectors, engine/valve covers, front timing chain covers, and small electric motors have benefited from this technology for many years.
Recent advances in the formulations have opened up new applications in automotive under the hood applications. Labeled, "BMC Dimension X", this new material technology is quickly finding its way into applications that require extremely tight molded dimensions and dimensional stability over a temperature range from -40°C to 150°C. Some of these applications include Electronic Throttle Controls (ETC), Air Control Valves (ACV), and transmission components.
This paper investigates the critical characteristics of these performance parts and the properties of "BMC Dimension X" which help make the system work.

Mechanical Properties of Laminates Fabricated Using Vacuum Infused Knitted Reinforcements
By: Art Wolfe
Company: Goodrich Corporation
Description:
The strength of various types of knit reinforcements (0/90, +/-45, quadraxials, etc.) are well understood for products fabricated using conventional techniques, including hand layup. Closed molding vacuum-assisted infusion manufacturing methods typically produce higher fiber content laminates, with a corresponding reduction in laminate thickness. The relative strengths of some vacuum-infused knitted reinforcements are presented here, when tested along the major fiber axes. It is shown that resin-infusion techniques can produce high-strength, low void content laminates when using reinforcements that are not specifically designed for infusion.

Mechanics Based Durability Modeling of FRP Bridge Deck
By: Hwai-Chung Wu
Company: Wayne State University
Description:
Fiber Reinforced Polymer (FRP) composites, especially lightweight sandwich structures, are rapidly finding their ways into civil infrastructure application. FRP composite panels are particularly attractive as bridge deck system due to their high strength, low density, and durability, which are of importance to the bridge industry. For civil engineering application, it is essential to determine the durability performance of FRP materials under weathering conditions, especially freeze-thaw and low temperature exposure.
Since load capacity and structural stiffness of FRP decks will likely deteriorate over time, it is necessary to develop robust mechanics models that accurately describe the combined effect of load and environmental exposure at the material level, taking account degradation mechanisms and their interactions. Such durability constitutive law can be established from accelerated laboratory testing. Laboratory testing should also be correlated to field performance. Therefore such material constitutive relationships can be input to general-purpose finite element analysis for design of bridge deck for long-term durability. All of the above issues will be discussed in this paper.

Low-Profile FRP Composite Deck as Replacement for Open Steel Grid Decks
By: Lei Zhao
Company: University of Central Florida
Description:
Replacing open steel grid decks that are commonly used in moveable bridges with a low-profile FRP deck can improve rider safety and reduce maintenance costs, while satisfying the strict weight requirement for such bridges. The performance of the new deck system, which includes fatigue, strength, connection to steel girders, and compatibility with a polymer wear surface, is being evaluated in full-scale two-span continuous configurations. The deck has successfully passed the preliminary strength and fatigue tests per AASHTO requirements. The FRP deck has also demonstrated that it can be quickly installed and its top bonds well with the wear surface.