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FiBrEgLaSs

FiBrEgLaSs. Materials Assingment By: David Wilksch. Manufacturing Processes;. Fibreglass is a material made up of extra fine glass fibres bonded together by a resin . Fibreglass is strong in tension and compression, but weak in shear- across it axis.

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FiBrEgLaSs

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  1. FiBrEgLaSs Materials Assingment By: David Wilksch

  2. Manufacturing Processes; • Fibreglass is a material made up of extra fine glass fibres bonded together by a resin. • Fibreglass is strong in tension and compression, but weak in shear- across it axis. Fibreglass is a composite material and is formally known as either; • Glass reinforced plastic • Fibre reinforced plastic/polymer These two types have differing methods of construction

  3. Manufacturing Processes; Glass Reinforced Plastic (GRP); • Made by using large furnaces to slowly melt the sand/chemical mix until it becomes liquid. • Its then extruded through bundles of tiny orifices as small as 9 micro-metres thick, before getting sized with a chemical solution. • They then get bundled together into rovings (process where filaments are spun into larger Ø threads before being implemented to a construction method, which includes....................

  4. Manufacturing Processes; GRP Construction Methods; • Hand lay up operation-(sheets of fibre glass, wetted with resin, placed in mold and pressed with steel rollers) • Spray lay up operation- similar to hand lay up, but resins and reinforcement are sprayed onto the mould with a chopper gun) • Pultrusion- (fibres are pulled from spools and coated with resin, then heat treated and cut to length)

  5. Manufacturing Processes; GRP Mould Making Process; • A ‘plug’ or ‘buck’ (which is an exact negative copy of the desired product to be made) is used. • It is usually made out of ‘a certain type of foam’ • It then gets sprayed with a releasing agent and a coloured gel coat for a harder, durable finish • After this point the mold is ready to be used in construction.

  6. Manufacturing Processes; Fibre Reinforced Plastic/Polymer (FRP); • Is made up of a polymer matrix reinforced with fibres • The fibres are usually fibreglass, carbon or arimid, while the polymer is a epoxy, vinylester or polyester thermosetting plastic. • To make FRP there are 2 distinct processes..............................

  7. Manufacturing Processes; Fibre Reinforced Plastic/Polymer (FRP); • Process 1- ‘The fibrous material is manufactured and formed’ • Process 2- ‘The fibrous material is bonded with the matrix during the molding process’

  8. Manufacturing Processes; Fibre Reinforced Plastic/Polymer (FRP); Process 1- ‘The fibrous material is manufactured and formed’ • This can be achieved in both 2 and 3 dimensional oreintations. • The main difference between the two methods is that the FRP is aligned along the X and Y axis for 2D, where for 3D the FRP is layed on the Z axis as well.

  9. Manufacturing Processes; Fibre Reinforced Plastic/Polymer (FRP); Process 2- ‘The fibrous material is bonded with the matrix during the molding process’ • 4 main ways you can do this. Which are: • Weaving-(weaved as per Process 1) • Braiding-(fibres fed through mandrels that vary in size. 45˚pattens possible unlike conventional weaving) • Knitting-(Talk to your granny) • Stitching-(This too)

  10. Manufacturing Processes; FRP Mould Making process; 2 categories- • Composite- Uses ‘pre-preg’ FRP which means plastics are fibre reinforced before being put through the mould • Wet- Combines the fibre reinforcement and the matrix during the moulding process • Some types of each are listed in the next slide................................................

  11. Manufacturing Processes; FRP Mould Making process;

  12. Manufacturing Processes; • The two most popular types of fibreglass are; • E-Glass- good insulation properties and will maintain its properties up to 816 ˚C • S-Glass- high tensile strength, stiffer than E glass and is the type to use if looking for max strength. • Other variants include C-Glass (chemical resitant), T-Glass (American C-Glass), A-Glass (bottles made into fibreglass), AR-Glass (alkali resistant glass)

  13. Uses; • Insulation- thermal, electrical and general • Door surrounds, window and over-door canopies, dormers, chimneys, coping systems, keystones and sills. • Translucent roofing panels • FRP tanks for both rainwater and sewerage • Pipes for drinking water, sewerage and gas • Bath hobs, spas and pools

  14. Defects; Structural failure can occur in FRP materials when: • Tensile forces stretch the matrix more than the fibres, causing the material to shear at the interface between matrix and fibres. • Tensile forces near the end of the fibres exceed the tolerances of the matrix, separating the fibres from the matrix. • Tensile forces can also exceed the tolerances of the fibres causing the fibres themselves to fracture leading to material failure.

  15. Enviromentals; • Fibreglass has a few issues when the time comes to bin the fibreglass product you may have. • Its hard for fibreglass returned to a virginal state, because the fibres are difficult to separate from the matrix which faces the same challenges in separating it into usable plastic, polymers and monomers. • Fibreglass does offer monetry and energy savings compared to its competition • Bio plastics and UV-degradable plastics will help in the future though

  16. Handling Recommendations; For fibreglass bats (glass-wool) there are a few things to keep in mind when handling it; Skin • Wear loose-fitting, long-sleeved clothing and long pants. • Do not tape sleeves or pants at wrists or ankles. • Wear gloves. • Do not scratch or rub your skin if fibre glass particles accumulate on your skin. • When you finish, wash skin or shower with mild soap and warm, running water.

  17. Handling Recommendations; Eyes • Wear safety glasses with side shields. • Do not rub your eyes while you are working with fibreglass. Be sure to complete clean up before rubbing your eyes or scratching your skin. Nose/Mouth/Throat • Wear a respirator

  18. Handling Recommendations; Installation & Clean-up • Do not handle fibreglass scrap more than necessary. • Be organized in cleaning your work area so that you dont spread fibres • Make sure all installed insulation is never left exposed in an occupied area. • Wash work clothes separately and wipe out washer after cycle is complete.

  19. Australian Standards; AS4859.1-Materials For Thermal Insulation AS 4748-2001-Acousticemission testing of fibreglass-insulated booms on elevating work platforms AS 3999-1992-Thermal insulation of dwellings - Bulk insulation AS 2764-2002-Fibre reinforced plastics (FRP) aluminium alloy gas cylinders - Hoop overwrapped

  20. Bibliography; • www.wikipedia.org • www.lungusa.org

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