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Inorganic Phosphate Textile Reinforced Cement composite moulds
Boekbijdrage - Boekhoofdstuk Conferentiebijdrage
SUMMARY
In order to meet the new demands of the industry, for example: reduction of production time, material reduction, cost saving and ecological aspects a new mould production technique will be presented. The aim of this research is the development of a mould technique which can replace the classic thermo harder or metal moulds, using textile reinforced cement. This mould type will even be applicable for the production of thermoplastic advanced composites.
Keywords: inorganic phosphate cement (IPC); textile reinforced concrete (TRC); moulds; thermoplastic; prototype.
Introduction
Through the early 1970's the composite industry experienced significant growth, this was driven by a demand to meet both styling needs and weight reduction of construction parts. In order to meet the new demands of the industry (ref.:3) but also the need to produce in a more ecological way, this research will present a mould technique to replace the conventional metal and thermo harder moulds. The aim of this work is to propose a new technique using textile reinforced cement composite to produce a mould which can be produced faster with less material and is useable at high temperatures.
Thermoplastics
Thermoplastic advanced composites are of great interest for meeting the needs of new challenges in the composite industry. Thermoplastics offer a number of important advantages over thermosets like better toughness and damage tolerance, rapid fabrication cycle and the possibility of assembling substructures by welding. In order to produce large thermoplastic composite parts, for example ships or windmill blades, new mould construction techniques need to be developed. The aim of this work is to propose a new techniques using textile reinforced cement composite to produce a mould for thermoplastic composites.
Textile reinforced concrete (TRC)
The mould will be produced using inorganic phosphate cement (IPC) in combination with random distributed chopped glass fibre textile reinforcement. IPC has been developed at the "Vrije Universiteit Brussel" and shows a neutral pH after hardening. Therefore, the glass fibres are hardly attacked by the concrete matrix. By using a fibre volume fraction which exceeds the critical fibre volume fraction, the fibres can ensure strength and stiffness at applied loads far exceeding the range in which matrix multiple cracking occurs. (ref.:1) Textile reinforced cementitious composites with glass fibres as reinforcement exhibit relatively high strength and ductility and thus provides an interesting new material for thin shells. Another big advantage is that it can resist high temperature, without producing toxic gasses and is also the absolute incombustibility, according to the European standard EN13501-1. All this advantages will make TRC an ideal material to develop a mould which can be used to produce thermoplastic composites.
Mould prototype
In this study moulds will be produced to test the possibilities of this new moulding technique. Several cases are worked out (ref.:2). One of the preliminary cases is the development of mould replacing the original thermo harder mould. Initial test (shrinkage measurements, the influence of temperature on the mass loss, production of moulds with different matrix compositions) were performed in order to optimise the behaviour of the matrix and the composite. The aim is to use these tests to optimize the material properties, shrinkage behaviour and surface quality. The future work of this development is to produce a mould capable to produce large thermoplastic composites. In the scope of this paper an experiential project will be setup in order to determine the possibilities using thermoplastics in a TRC mould.
References
(1) J. Blom , H. Cuypers P,. Van Itterbeeck, J. Wastiels, Modelling the behaviour of Textile Reinforced Cementitious composites under bending, Prague, Fibre Concrete 4th International Conference, p.205-210, 2007
(2) S. Faignet, P. Bauweraerts, J. Wastiels and X. Wu ,Materials Processing Technology Mineral Polymer tooling system for making prototype fibre reinforced composite parts V.U.B, Belgium,Journal of Materials Processing Technology 48 (1995) 757-764
(3) Global Composites Market 2005-2010: Opportunities, Markets and Technologies Lucintel January 1, 2005- Pub ID: EC1469876
In order to meet the new demands of the industry, for example: reduction of production time, material reduction, cost saving and ecological aspects a new mould production technique will be presented. The aim of this research is the development of a mould technique which can replace the classic thermo harder or metal moulds, using textile reinforced cement. This mould type will even be applicable for the production of thermoplastic advanced composites.
Keywords: inorganic phosphate cement (IPC); textile reinforced concrete (TRC); moulds; thermoplastic; prototype.
Introduction
Through the early 1970's the composite industry experienced significant growth, this was driven by a demand to meet both styling needs and weight reduction of construction parts. In order to meet the new demands of the industry (ref.:3) but also the need to produce in a more ecological way, this research will present a mould technique to replace the conventional metal and thermo harder moulds. The aim of this work is to propose a new technique using textile reinforced cement composite to produce a mould which can be produced faster with less material and is useable at high temperatures.
Thermoplastics
Thermoplastic advanced composites are of great interest for meeting the needs of new challenges in the composite industry. Thermoplastics offer a number of important advantages over thermosets like better toughness and damage tolerance, rapid fabrication cycle and the possibility of assembling substructures by welding. In order to produce large thermoplastic composite parts, for example ships or windmill blades, new mould construction techniques need to be developed. The aim of this work is to propose a new techniques using textile reinforced cement composite to produce a mould for thermoplastic composites.
Textile reinforced concrete (TRC)
The mould will be produced using inorganic phosphate cement (IPC) in combination with random distributed chopped glass fibre textile reinforcement. IPC has been developed at the "Vrije Universiteit Brussel" and shows a neutral pH after hardening. Therefore, the glass fibres are hardly attacked by the concrete matrix. By using a fibre volume fraction which exceeds the critical fibre volume fraction, the fibres can ensure strength and stiffness at applied loads far exceeding the range in which matrix multiple cracking occurs. (ref.:1) Textile reinforced cementitious composites with glass fibres as reinforcement exhibit relatively high strength and ductility and thus provides an interesting new material for thin shells. Another big advantage is that it can resist high temperature, without producing toxic gasses and is also the absolute incombustibility, according to the European standard EN13501-1. All this advantages will make TRC an ideal material to develop a mould which can be used to produce thermoplastic composites.
Mould prototype
In this study moulds will be produced to test the possibilities of this new moulding technique. Several cases are worked out (ref.:2). One of the preliminary cases is the development of mould replacing the original thermo harder mould. Initial test (shrinkage measurements, the influence of temperature on the mass loss, production of moulds with different matrix compositions) were performed in order to optimise the behaviour of the matrix and the composite. The aim is to use these tests to optimize the material properties, shrinkage behaviour and surface quality. The future work of this development is to produce a mould capable to produce large thermoplastic composites. In the scope of this paper an experiential project will be setup in order to determine the possibilities using thermoplastics in a TRC mould.
References
(1) J. Blom , H. Cuypers P,. Van Itterbeeck, J. Wastiels, Modelling the behaviour of Textile Reinforced Cementitious composites under bending, Prague, Fibre Concrete 4th International Conference, p.205-210, 2007
(2) S. Faignet, P. Bauweraerts, J. Wastiels and X. Wu ,Materials Processing Technology Mineral Polymer tooling system for making prototype fibre reinforced composite parts V.U.B, Belgium,Journal of Materials Processing Technology 48 (1995) 757-764
(3) Global Composites Market 2005-2010: Opportunities, Markets and Technologies Lucintel January 1, 2005- Pub ID: EC1469876
Boek: Proceedings (CD-ROM) of the 17 th International conference on Composite Materials, Edinburgh, UK, 27-31 July 2009
Aantal pagina's: 10
Jaar van publicatie:2009
Trefwoorden:inorganic phosphate cement (IPC), textile reinforced concrete (TRC), moulds, thermoplastic, prototype