ebb 427 (6) pultrusion hazizan

8/3/2019 EBB 427 (6) Pultrusion Hazizan

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EBB 427 Application and Technology ofEngineering Polymers (Second Half)

Dr. Hazizan Md Akil

School of Materials and Mineral Resources EngineeringEngineering Campus, USM.

PULTRUSION PROCESSINGTECHNOLOGY


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Pultrusion Technology

Introduction

Pultrusion is a continuous, automated closed-mouldingprocess that is cost effective for high volume productionof constant cross section parts.

Due to uniformity of cross-section, resin dispersion, fiber

distribution & alignment, excellent composite structuralmaterials can be fabricated by Pultrusion

The basic process usually involves pulling of continuousfibers through a bath of resin, blended with a catalyst and

then into pre-forming fixtures where the section ispartially pre-shaped & excess resin is removed


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Introduction

It is then passed through a heated die, which determinesthe sectional geometry and finish of the final product.

The profiles produced with this process can compete withtraditional metal profiles made of steel & aluminium for

strength & weight. The Pultrusion process has developed slowly compared

to other composite fabrication processes

The initial pultrusion patent in the United States was

issued in 1951


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Introduction

In the early 1950s pultrusion machines for the productionof simple solid rod stock were in operation at severalplants

Most of these machines were the intermittent pull type

In the mid-1950s, continuous pull machines wereavailable

The late 1950s were producing pultruded structuralshapes and by 1970, there has been a dramatic increase

in market acceptance, technology development, andPultrusion industry sophistication.


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Introduction


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The Process

The process begins when reinforcing fibers are pulledfrom a series of creels.

The fibers proceed through a bath, where they areimpregnated with formulated resin

The resin-impregnated fibers are preformed to the shapeof the profile to be produced.

This composite material is then passed through a heatedsteel die that has been machined precisely to the final

shape of the part to be manufactured


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The Process

Heat initiates an exothermic reaction thus curing thethermosetting resin matrix

The profile is continuously pulled and exits the mould asa hot, constant cross sectional member

The profile cools in ambient or forced air, or assisted bywater.

The product emerges from the puller mechanism and iscut to the desired length by an automatic, flying cutoff

saw.


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The Process


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Advantages

Pultrusion is the most cost-effective method of producingfiber-reinforced composite structural profiles

The process is capable of producing high performancecomposite of various continuous profiles, typically

products such as light-weight corrosion free structures,electrical non-conductive systems, off-shore platformsand many other innovative new products from Researchand Development to mass production and

commercialization There are numerous advantages of pultruded Fiber

Reinforced Polymer (FRP) profiles of which can besummarized as shown in Table 1.


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Pultrusion TechnologyFeatures Description Benefits Applications

Strong

Unit strength in tension &compression is approx. 20 x

that of steel when theseproperties are combined on

the basis of unit density

Optional strength as desired.Exceptionally high impactstrength reduces damage

potential

Structural process equipmentsupport. Tank supports.

Cooling tower ancillaries.Flooring supports. Trusses &

joints.

Light WeightDensity of pultruded components

is about 20% of steel and60% of aluminium

Higher performance at less weight.Lower shipping, handling &

installation costs. Lessoperational energy demand.

Automotive leaf springs & bumpers.Prefabricated walkways &

platforms. Bus components.

CorrosionResistant

Unaffected by exposure to a greatvariety of corrosive

environment & chemicals.

Minimum maintenance costs. Longterm safety. Longer life.

Chemical plant hand railings,gratings, walkways & bridges.

Cable trays. Pipe supports.

ElectricalInsulation

Provides strength & rigidity withdielectric properties.

Lesser no. of components. Non-

magnetic & safe. Predictableinsulation values for wide

range of frequencies.

Ladders, Cable trays. Switch gearcomponents. Mounting bracesand backboards.

ThermalInsulation

Pultruded components have a lowthermal conductivity, 1/250

of aluminium & 1/60 of steel.

Reduces installation thickness.Eliminates condensation

problems. Reduces energyoperation requirements.

Bulk head frames. Walk inrefrigerator door jams. Windowframes. Insulated roll up panel

doors.

ConsolidationMany individual components can

be combined into a large

profile.

Reduced assembly cost. Reducedinventory. Fewer parts

improve reliability.

Window latch supports. Roll up door

DimensionalStability

Pultruded components are highlyresistant to warping

stretch/swelling over a widerange of temperature &

stresses.

No permanent deformation underhigh stress. Close tolerances.

Spring bumpers. Crossing gate arms.Scrubber components.

Safety

The pultruded components arevery strong & safe to work

with. They are microbes andinsect proof.

Many gratings suffer from theproblem of microbes etc. dueto wet or unhygienic working

conditions.

This property makes them idealchoice for pharmaceutical &

food industries.


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Applications of Pultrusion Technology

Application Areas of Pultrusion

Electrical

32%

Building &

Construction

17%

Transport

10%

Industrial

17%

Recreation

7%

Other

17%


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Fig. 3: Stork Bridge, Switzerland (Glass Fiber Reinforced Polymer) built in 1996


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Kempt Bridge Switzerland (FRP Composite Pedestrian Bridge built in year 2001)


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Kolding Bridge, Denmark (GRP composite bridge) was opened on 18th July, 1997)


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Grating products for sewer or drainage system-reducing the maintenance cost


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ebb 427 (6) pultrusion hazizan

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