Thermosets and Composites

Chapter 1 - Outline of the actual situation of plastics versus conventional materials1.1 Polymers: the industrial and economic reality compared to traditional materials1.1.1 Plastic and metal consumption1.1.2 Mechanical properties1.1.2.1 Intrinsic mechanical properties1.1.2.2 Specific mechanical properties1.1.3 Thermal and electrical properties1.1.4 Durability1.1.5 Material costs1.1.5.1 Cost per weight of various materials1.1.5.2 Cost per volume of various materials1.1.5.3 [Performances/cost per litre] ratios of various materials1.2 What are thermosets, composites and hybrids?1.2.1 Thermosets1.2.2 Polymer composites1.2.3 Hybrid materials1.3 Plastics: an answer to the main designer's problems1.3.1 Economical requirements 1.3.2 Technical requirements1.3.3 Marketing requirements1.3.4 Environmental requirements1.3.5 Some weaknesses of the polymer materials1.4 Outline of the technical and economic possibilities of processing1.4.1 Thermoset processing1.4.1.1 Moulding the solid thermosets1.4.1.2 Moulding the liquid thermosets1.4.1.3 Secondary processing1.4.2 Composite processing1.4.2.1 Primary processes1.4.2.2 Secondary processing1.4.2.3 Repaire possibilities: a significant composite advantage1.4.3 Hybrid processing1.5 Environmental constraints1.5.1 Toxicity and pollution1.5.2 The recycling of polymers1.6 The final material/process/cost compromise

Chapter 2 - The plastic industry: economic overview2.1 Overview of the global plastic industry2.2 Market shares of the various thermoset families in the main industrialized countries2.3 Market shares of composites2.4 Market shares of the main application sectors2.5 Importance of the various processing modes2.6 The european market2.7 The north american market2.8 Consumption growth trends2.8.1 Thermosets2.8.2 Composites2.9 Structure of the plastic processing industry 2.10 Plastic costs2.10.1 Raw material costs2.10.2 Examples of additive costs2.10.3 Reinforcement costs2.10.4 Processing costs2.10.5 Examples of part costs2.10.6 Assembly, operating and maintenance costs: three factors to favour composites2.10.6.1 Assembly cost savings 2.10.6.2 Operating cost savings2.10.6.3 Maintenance cost savings2.11 Survey of main markets 2.11.1 Automotive and transportation 2.11.1.1 Thermosets and composite in the automobile industry2.11.1.2 Composites in railway applications2.11.2 Furniture and bedding2.11.2.1 Interior and communal furniture 2.11.2.2 Outdoor furniture, street furniture2.11.3 Aeronautics, space, armaments2.11.3.1 Advantages of composite for aerospace applications2.11.3.2 Disadvantages of composites2.11.3.3 Examples of opertional or development parts 2.11.4 Shipbuilding, offshore, nautical sports 2.11.4.1 Composites in the shipbuilding sector2.11.4.2 Composites in offshore oil rig construction2.11.4.3 Barriers to composite use2.11.5 Anti-corrosion equipment, mechanics, industry, tools 2.11.6 Electricity, electronics 2.11.7 Electric household appliances, refrigeration, office automation2.11.8 Medical 2.11.9 Sports and leisure 2.11.10 Packaging 2.11.11 Art, decoration 2.11.12 Miscellaneous applications2.12 Applications of the main thermoset and composite families2.12.1 Polyurethanes and polyurea2.12.1.1 Foam application examples2.12.1.2 RIM application examples2.12.1.3 Elastomer application examples2.12.1.4 Coating and sealing application examples2.12.1.5 Polyurea 2.12.2 Unsaturated polyesters 2.12.2.1 Consumption2.12.2.2 Applications2.12.3 Phenolic resins2.12.3.1 Consumption2.12.3.2 Applications2.12.4 Melamine and urea-formaldehyde resins (amino resins)2.12.4.1 Consumption2.12.4.2 Applications2.12.5 Epoxide resins2.12.5.1 Consumption2.12.5.2 Applications2.12.6 Polyimides 2.12.6.1 Consumption2.12.6.2 Applications2.12.7 Silicones2.12.7.1 Consumption2.12.7.2 Applications2.12.8 Polycyanates or cyanate esters2.12.8.1 Consumption2.12.8.2 Applications2.12.9 DCPD2.12.9.1 Consumption2.12.9.2 Applications2.12.10 Furane resins2.12.10.1 Consumption2.12.10.2 Applications2.13 Application examples of the main reinforcements2.13.1 Glass fibres2.13.1.1 Consumption2.13.1.2 Applications2.13.2 Aramid fibres2.13.2.1 Consumption2.13.2.2 Applications2.13.3 Carbon fibres2.13.3.1 Consumption2.13.3.2 Applications2.13.4 Sustainable natural fibres 2.13.4.1 Consumption2.13.4.2 Applications2.13.5 Other fibres and reinforcements2.13.6 Self-reinforcing polymers2.13.7 Sandwich composites2.13.8 Hybrids2.14 Applications of the main processing methods2.14.1 Thermoplastic composites2.14.2 SMC, BMC, ZMC2.14.3 RTM2.14.4 Hand lay-up and spray lay-up 2.14.5 Pultrusion2.14.6 Filament winding2.14.7 Prepreg applications2.14.8 Centrifugal moulding2.14.9 Continuous sheet moulding

Chapter 3 - Basic criteria for the selection of thermosets3.1 Evaluation of plastic properties3.1.1 Thermal behaviour3.1.2 Low temperture behaviour 3.1.3 Mechanical properties 3.1.4 Long-term mechanical properties 3.1.5 Long-term light and UV resistance3.1.6 Chemical resistance by immersion or contact 3.1.7 Electrical properties 3.1.8 Gas permeability 3.1.9 Flammability3.1.10 Optical properties3.2 ISO standards concerning polymer testing 3.2.1 Moulding of test specimens 3.2.2 Mechanical properties 3.2.3 Thermomechanical properties 3.2.4 Long-term properties3.2.5 Fluid contact behaviour3.2.6 Electrical properties3.2.7 Oxygen indes, flammability, smoke generation3.2.8 Optical properties3.3 Material selection3.4 Precision of the moulded parts3.5 Schematic comparison of thermoset and composite properties

Chaper 4 - Detailed accounts of thermoset resins for moulding and composit matrices4.1 Polyurethanes, polyureas (PUR)4.1.1 General properties4.1.2 Thermal behaviour4.1.3 Optical properties4.1.4 Mechanical properties4.1.5 Ageing4.1.6 Electrical properties4.1.7 Joining4.1.8 Foams4.1.9 Specific ISO standards concerning polyurethanes4.1.10 Trade name examples4.1.11 Property tables4.2 Unsaturated polyesters (UP)4.2.1 General properties4.2.2 Thermal behaviour4.2.3 Optical properties4.2.4 Mechanical properties4.2.5 Ageing4.2.6 Electrical properties4.2.7 Joining4.2.8 Specific ISO standards concerning polyesters4.2.9 Trade name examples4.2.10 Property tables4.3 Phenolic resins (PF)4.3.1 General properties4.3.2 Thermal behaviour4.3.3 Optical properties4.3.4 Mechanical properties4.3.5 Ageing4.3.6 Electrical properties4.3.7 Joining4.3.8 Foams4.3.9 Specific ISO standards concerning phenolic resins4.3.10 Trade name examples4.3.11 Property tables4.4 The amino resins: melamine (MF) and urea-formaldehyde (UF)4.4.1 General properties4.4.2 Thermal behaviour4.4.3 Optical properties4.4.4 Mechanical properties4.4.5 Ageing4.4.6 Electrical properties4.4.7 Joining4.4.8 Foams4.4.9 Specific ISO standards concerning amino resins4.4.10 Trade name examples4.4.11 Property tables4.5 Exposides or epoxy resins (EP)4.5.1 General properties4.5.2 Thermal behaviour4.5.3 Optical properties4.5.4 Mechanical properties4.5.5 Ageing4.5.6 Electrical properties4.5.7 Joining4.5.8 Foamed epoxies and syntactic foams4.5.9 Specific ISO standards concerning expoxides4.5.10 Trade name examples4.5.11 Property tables4.6 Polyimides (PI)4.6.1 General properties4.6.2 Thermal behaviour4.6.3 Optical properties4.6.4 Mechanical properties4.6.5 Ageing4.6.6 Electrical properties4.6.7 Joining4.6.8 Foamed polyimides and syntactic foams4.6.9 Trade name examples4.6.10 Property tables4.7 Silicones or polysiloxanes (MQ, PMQ, PVMQ, VMQ or SI) and fluorosilicones (FMQ, FVMQ or FSI)4.7.1 General properties4.7.2 Thermal behaviour4.7.3 Optical properties4.7.4 Mechanical properties4.7.5 Ageing4.7.6 Electrical properties4.7.7 Joining4.7.8 Foamed silicones and syntactic foams4.7.9 Specific ISO standards concerning silicones4.7.10 Trade name examples4.7.11 Property tables4.8 Polycyanates or cyanates esters (Cy)4.8.1 General properties4.8.2 Thermal behaviour4.8.3 Mechanical properties4.8.4 Ageing4.8.5 Electrical properties4.8.6 Syntactic foams4.8.7 Trade name examples4.8.8 Property tables4.9 Other thermosets4.9.1 Dicyclopentadiene (DCPD)4.9.1.1 General properties4.9.1.2 Thermal behaviour and ageing4.9.1.3 Mechanical properties4.9.1.4 Electrical properties4.9.1.5 Joining4.9.1.6 Trade name examples4.9.1.7 Property tables4.9.2 Furans4.9.2.1 General properties4.9.2.2 Properties and ageing4.9.2.3 Trade name examples

Chaper 5 - Thermoset processing5.1 Solid thermoset processing5.1.1 Compression moulding5.1.2 Compression transfer moulding5.1.3 Injection moulding5.1.4 Extrusion5.2 Liquid thermoset processing5.2.1 Casting5.2.2 Liquid injection moulding (LIM)5.2.3 Reaction injection moulding (RIM)5.2.4 Rotational moulding5.2.5 Foaming5.2.6 Composite processes5.3 Thermoset machining5.4 Thermoset assembly5.4.1 Adhesive bonding5.4.2 Mechanical assembly

Chapter 6 - Composites6.1 Definitions6.2 Reminder of some basic principles 6.3 Composite mechanical performances according to the reinforcement type 6.3.1 Reinforcement by randomly distributed short fibres 6.3.2 Reinforcement by arranged continuous fibres 6.3.2.1 Unidirectional reinforcement 6.3.2.2 Reinforcement with two orthogonal layers 6.3.3 General approximate method for strength estimation 6.4 Composite Matrices Thermosets 6.4.1 Thermosets 6.4.2 Thermoplastics 6.4.3 Influence of the matrix on the composite properties 6.5 Reinforcements 6.5.1 Fibres 6.5.1.1 Glass fibres for polymer reinforcement 6.5.1.3 Aramid fibres (AF) for polymer reinforcement 6.5.1.4 Comparison of the three main types of fibres 6.5.1.5 Sustainable natural vegetal fibres 6.5.1.6 Other mineral fibres 6.5.1.7 Other textile fibres 6.5.1.8 Industrial fibres 6.5.2 The different fibre forms used for reinforcement 6.5.3 Foams for sandwich technology 6.5.4 Honeycombs 6.5.5 Plywood and wood 6.5.6 Influence of the core on the sandwich properties 6.5.7 Nanofillers 6.6. Intermediate semi-Manufactured materials 6.6.1. SMC, bulk compounds, prepregs 6.6.2. Glass mat thermoplastics (GMTs) and prepregs 6.6.3. Examples of intermediate semi-manufactured composites 6.6.4. Advanced all-polymer prepregs or self-reinforced polymers 6.7 Composite Processing 6.7.1 Thermoset composites 6.7.2 Thermoplastic composites 6.7.3 Sandwich composites 6.7.4 Finishing operations 6.7.5 Repairing composites 6.8 Examples of composite characteristics 6.8.1 Basic principles 6.8.2 Nanocomposites 6.8.3 Short fibre composites 6.8.3.1 Significant parameters 6.8.3.2 Short glass fibres 6.8.3.3 Short carbon fibres 6.8.3.4 Short aramid fibres 6.8.4 Long fibre reinforced plastics: LFRT and BMC 6.8.5 "Continuous" fibre composites 6.8.6 Sandwich composites 6.8.7 Foamed composites 6.8.7.1 Property examples of RRIM, SRRIM 6.8.7.2 Foamed matrix composites 6.8.7.3 Syntactic foams 6.8.8 Hybrid composites 6.8.9 Conductive composites

Chapter 7 - Future prospects for thermosets and composites 7.1 The Laws and requirements of the market 7.2 Thermoset and composite answers and assets 7.3 Markets: What drives what? The forces driving development 7.3.1 Consumption trends 7.3.2 Requirements of the main markets 7.4 Cost Savings 7.4.1 Material costs 7.4.2 Hybrids 7.4.3 Processing costs 7.4.3.1 Example of compounding integrated on the process line 7.4.3.2 New or modified processes 7.4.3.3 Integrating finishing in the process 7.4.4 Low-cost tool examples 7.5 Material upgrading and Competition 7.5.1 Carbon nanotubes (CNT) 7.5.2 Molecular reinforcement 7.5.3 Polymer nanotubes 7.5.4 Nanofillers 7.5.5 Short fibre reinforced thermoplastics to compete with LFRT 7.5.6 Thermoplastic and thermoset competition 7.5.7 3D reinforcements compete with 2D 7.5.8 Carbon fibres compete with glass fibres 7.5.9 New high performance polymers 7.6 The immediate future seen through recent patents 7.6.1 Analysis of patents by polymer type 7.6.2 Analysis of patents by reinforcement type 7.6.3 Analysis of patents by structure and process type 7.7 The immediate future seen through recent awards 7.8 Environmental concerns 7.8.1 Recycling of thermosets and composites 7.8.1.1 Collection and pre-treatment of wastes 7.8.1.2 The main recycling routes 7.8.1.3 Thermoset and composite specifics 7.8.1.4 Thermoset and composite recyclates: mechanical and calorific properties 7.8.1.5 Recycling costs 7.8.2 Sustainable standard and high-performance reinforcements 7.8.3 Sustainable and biodegradable components for matrices 7.8.4 Examples of sustainable composites

Conclusion