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01.03.2021, admin
Fiberglass American English , or fibreglass Commonwealth English is a common type of fiber-reinforced plastic using glass fiber. The fibers may be randomly arranged, flattened into a sheet called a chopped strand mat , or woven into a fabric.
The plastic matrix may be a thermoset polymer matrix �most often based on thermosetting polymers such as epoxy , polyester resin , or vinylester �or a thermoplastic. Cheaper and more flexible than carbon fiber , it is stronger than many metals by weight, is non- magnetic , non- conductive , transparent to electromagnetic radiation , can be molded into complex shapes, and is chemically inert under many circumstances. Applications include aircraft, boats, automobiles, bath tubs and enclosures, swimming pools , hot tubs , septic tanks , water tanks , roofing, pipes, cladding, orthopedic casts , surfboards , and external door skins.
Because glass fiber itself is sometimes referred to as "fiberglass", the composite is also called "fiberglass reinforced plastic". This article will adopt the convention that "fiberglass" refers to the complete glass fiber reinforced composite material, rather than only to the glass fiber within it.
Glass fibers have been produced for centuries, but the earliest patent was awarded to the Prussian inventor Hermann Hammesfahr � in the U. Mass production of glass strands was accidentally discovered in when Games Slayter , a researcher at Owens-Illinois , directed a jet of compressed air at a stream of molten glass and produced fibers. A patent for this method of producing glass wool was first applied for in Originally, Fiberglas was a glass wool with fibers entrapping a great deal of gas, making it useful as an insulator, especially at high temperatures.
A suitable resin for combining the fiberglass with a plastic to produce a composite material was developed in by du Pont. The first ancestor of modern polyester resins is Cyanamid 's resin of Peroxide curing systems were used by then. This reduced the insulation properties to values typical of the plastic, but now for the first time, the composite showed great strength and promise as a structural and building material.
Many glass fiber composites continued to be called "fiberglass" as a generic name and the name was also used for the low-density glass wool product containing gas instead of plastic. Ray Greene of Owens Corning is credited with producing the first composite boat in but did not proceed further at the time due to the brittle nature of the plastic used. In Russia was reported to have constructed a passenger boat of plastic materials, and the United States a fuselage and wings of an aircraft.
Unlike glass fibers used for insulation, for the final structure to be strong, the fiber's surfaces must be almost entirely free of defects, as this permits the fibers to reach gigapascal tensile strengths.
If a bulk piece of glass were defect-free, it would be equally as strong as glass fibers; however, it is generally impractical to produce and maintain bulk material in a defect-free state outside of laboratory conditions. The process of manufacturing fiberglass is called pultrusion.
The manufacturing process for glass fibers suitable for reinforcement uses large furnaces to gradually melt the silica sand, limestone , kaolin clay , fluorspar , colemanite , dolomite and other minerals until a liquid forms.
It is then extruded through bushings, which are bundles of very small orifices typically 5�25 micrometres in diameter for E-Glass, 9 micrometres for S-Glass. These filaments are then sized coated with a chemical solution. The individual filaments are now bundled in large numbers to provide a roving. The diameter of the filaments, and the number of filaments in the roving, determine its weight , typically expressed in one of two measurement systems:.
These rovings are then either used directly in a composite application such as pultrusion , filament winding pipe , gun roving where an automated gun chops the glass into short lengths and drops it into a jet of resin, projected onto the surface of a mold , or in an intermediary step, to manufacture fabrics such as chopped strand mat CSM made of randomly oriented small cut lengths of fiber all bonded together , woven fabrics, knit fabrics or unidirectional fabrics.
Chopped strand mat or CSM is a form of reinforcement used in fiberglass. It consists of glass fibers laid randomly across each other and held together by a binder.
It is typically processed using the hand lay-up technique, where sheets of material are placed on a mold and brushed with resin. Because the binder dissolves in resin, the material easily conforms to different shapes when wetted out. After the resin cures, the hardened product can be taken from the mold and finished.
Using chopped strand mat gives the fiberglass isotropic in-plane material properties. An individual structural glass fiber is both stiff and strong in tension and compression �that is, along its axis. Although it might be assumed that the fiber is weak in compression, it is actually only the long aspect ratio of the fiber which makes it seem so; i.
Therefore, if a collection of fibers can be arranged permanently in a preferred direction within a material, and if they can be prevented from buckling in compression, the material will be preferentially strong in that direction. Furthermore, by laying multiple layers of fiber on top of one another, with each layer oriented in various preferred directions, the material's overall stiffness and strength can be efficiently controlled.
In fiberglass, it is the plastic matrix which permanently constrains the structural glass fibers to directions chosen by the designer.
With chopped strand mat, this directionality is essentially an entire two-dimensional plane; with woven fabrics or unidirectional layers, directionality of stiffness and strength can be more precisely controlled within the plane.
A fiberglass component is typically of a thin "shell" construction, sometimes filled on the inside with structural foam, as in the case of surfboards. The component may be of nearly arbitrary shape, limited only by the complexity and tolerances of the mold used for manufacturing the shell.
The mechanical functionality of materials is heavily reliant on the combined performances of both the resin AKA matrix and fibers. Naming and use: pure silica silicon dioxide , when cooled as fused quartz into a glass with no true melting point, can be used as a glass fiber for fiberglass but has the drawback that it must be worked at very high temperatures.
In order to lower the necessary work temperature, other materials are introduced as "fluxing agents" i. Ordinary A-glass "A" for "alkali-lime" or soda lime glass, crushed and ready to be remelted, as so-called cullet glass, was the first type of glass used for fiberglass.
E-glass "E" because of initial Electrical application , is alkali-free and was the first glass formulation used for continuous filament formation. It now makes up most of the fiberglass production in the world, and also is the single largest consumer of boron minerals globally. It is susceptible to chloride ion attack and is a poor choice for marine applications.
S-glass "S" for "stiff" is used when tensile strength high modulus is important and is thus an important building and aircraft epoxy composite it is called R-glass, "R" for "reinforcement" in Europe. C-glass "C" for "chemical resistance" and T-glass "T" is for "thermal insulator"�a North American variant of C-glass are resistant to chemical attack; both are often found in insulation-grades of blown fiberglass.
Fiberglass is an immensely versatile material due to its lightweight, inherent strength, weather-resistant finish and variety of surface textures. The development of fiber-reinforced plastic for commercial use was extensively researched in the s. It was of particular interest to the aviation industry.
A means of mass production of glass strands was accidentally discovered in when a researcher at Owens-Illinois directed a jet of compressed air at a stream of molten glass and produced fibers. After Owens merged with the Corning company in , Owens Corning adapted the method to produce its patented "Fiberglas" one "s".
A suitable resin for combining the "Fiberglas" with a plastic was developed in by du Pont. The first ancestor of modern polyester resins is Cyanamid's of During World War II, fiberglass was developed as a replacement for the molded plywood used in aircraft radomes fiberglass being transparent to microwaves.
Its first main civilian application was for the building of boats and sports car bodies, where it gained acceptance in the s. Its use has broadened to the automotive and sport equipment sectors. In the production of some products, such as aircraft, carbon fiber is now used instead of fiberglass, which is stronger by volume and weight.
Advanced manufacturing techniques such as pre-pregs and fiber rovings extend fiberglass's applications and the tensile strength possible with fiber-reinforced plastics. Fiberglass is also used in the telecommunications industry for shrouding antennas , due to its RF permeability and low signal attenuation properties. It may also be used to conceal other equipment where no signal permeability is required, such as equipment cabinets and steel support structures, due to the ease with which it can be molded and painted to blend with existing structures and surfaces.
Other uses include sheet-form electrical insulators and structural components commonly found in power-industry products. Because of fiberglass's lightweight and durability, it is often used in protective equipment such as helmets. Many sports use fiberglass protective gear, such as goaltenders' and catchers' masks. Storage tanks can be made of fiberglass with capacities up to about tonnes. Smaller tanks can be made with chopped strand mat cast over a thermoplastic inner tank which acts as a preform during construction.
Much more reliable tanks are made using woven mat or filament wound fiber, with the fiber orientation at right angles to the hoop stress imposed in the sidewall by the contents. Such tanks tend to be used for chemical storage because the plastic liner often polypropylene is resistant to a wide range of corrosive chemicals. Fiberglass is also used for septic tanks. Glass-reinforced plastics are also used to produce house building components such as roofing laminate, door surrounds, over-door canopies, window canopies and dormers, chimneys, coping systems, and heads with keystones and sills.
The material's reduced weight and easier handling, compared to wood or metal, allows faster installation. Mass-produced fiberglass brick-effect panels can be used in the construction of composite housing, and can include insulation to reduce heat loss. In rod pumping applications, fiberglass rods are often used for their high tensile strength to weight ratio. Fiberglass rods provide an advantage over steel rods because they stretch more elastically lower Young's modulus than steel for a given weight, meaning more oil can be lifted from the hydrocarbon reservoir to the surface with each stroke, all while reducing the load on the pumping unit.
Fiberglass rods must be kept in tension, however, as they frequently part if placed in even a small amount of compression. The buoyancy of the rods within a fluid amplifies this tendency. Filament winding is a fabrication technique mainly used for manufacturing open cylinders or closed-end structures pressure vessels or tanks.
The process involves winding filaments under tension over a male mandrel. The mandrel rotates while a wind eye on a carriage moves horizontally, laying down fibers in the desired pattern.
The most common filaments are carbon or glass fiber and are coated with synthetic resin as they are wound. Once the mandrel is completely covered to the desired thickness, the resin is cured; often the mandrel is placed in an oven to achieve this, though sometimes radiant heaters are used with the mandrel still turning in the machine.
Once the resin has cured, the mandrel is removed, leaving the hollow final product. For some products such as gas bottles, the 'mandrel' is a permanent part of the finished product forming a liner to prevent gas leakage or as a barrier to protect the composite from the fluid to be stored.
Filament winding is well suited to automation, and there are many applications, such as pipe and small pressure vessels that are wound and cured without any human intervention.
The Fiberglass Panels For Boat Building Data controlled variables for winding are fiber type, resin content, wind angle, tow or bandwidth and thickness of the fiber bundle. The angle at which the fiber has an effect on the properties of the final product. A high angle "hoop" will provide circumferential or "burst" strength, while lower angle patterns polar or helical will provide greater longitudinal tensile strength.
Products currently being produced using this technique range from pipes, golf clubs, Reverse Osmosis Membrane Housings, oars, bicycle forks, bicycle rims, power and transmission poles, pressure vessels to missile casings, aircraft fuselages and lamp posts and yacht masts. A release agent, usually in either wax or liquid form, is applied to the chosen mold to allow the finished product to be cleanly removed from the mold.
Resin�typically a 2-part thermoset polyester, vinyl, or epoxy�is mixed with its hardener and applied to the surface. Sheets of fiberglass matting are laid into the mold, then more resin mixture is added using a brush or roller. The material must conform to the mold, and air must not be trapped between the fiberglass and the mold. Additional resin is applied and possibly additional sheets of fiberglass. Hand pressure, vacuum or rollers are used to be sure the resin saturates and fully wets all layers, and that any air pockets are removed.
The work must be done quickly before the resin starts to cure unless high-temperature resins are used which will not cure until the part is warmed in an oven. The fiberglass spray lay-up process is similar to the hand lay-up process but differs in the application of the fiber and resin to the mold.
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