Title: Processing of Hollow Glass Sphere/Polyester/Glass Fiber Sheet Molding Composites

Authors: Arielle Berman, Edward DiLoreto, Yong Wu, Troy Ista, Andrew D’Souza, Robert Moon, and Kyriaki Kalaitzidou

DOI: 10.33599/nasampe/s.19.1482

Abstract: The development of lightweight polymer-glass fiber (GF) composites is a major step towards more environmentally sustainable automobiles. By altering the commonly used industry polymer Unsaturated Polyester Resin (UPR) with hollow glass spheres (HGS) of various characteristics, one can create a novel resin matrix for glass fiber composites. The different glass bubbles, with their low densities ranging from 0.28-0.46 g/cm3, allow for an increase in glass fiber loading while still decreasing the weight of the final composite produced using sheet molding compounds (SMC). Thorough calibration of the SMC line’s glass fiber and resin mass flow rate settings is a crucial step in achieving the desired glass fiber loading and composite density. Once completed, any changes in density of the composite can be solely attributed to the addition of hollow glass spheres. It is necessary to achieve proper dispersion of each of the types of glass spheres in order to minimize aggregates which may cause stress concentrations and, thus, decreased mechanical properties. Dispersion of HGS and GF is characterized with Scanning Electron Microscopy and optical imaging, while acetone dissolution is utilized to assess the GF loading of the SMC prior to compression molding.

References: [1] K. Friedrich, A.A. Almajid, "Manufacturing Aspects of Advanced Polymer Composites for Automotive Applications." Applied Composite Materials 20(2) (2013): 107-128. 10.1007/s10443-012-9258-7 [2] M. Pervaiz, S. Panthapulakkal, K. Birat, M. Sain, J. Tjong, "Emerging trends in automotive lightweighting through novel composite materials." Materials Sciences and Applications 7(01) (2016): 26. [3] E.M. Wouterson, F.Y.C. Boey, X. Hu, S.C. Wong, "Specific properties and fracture toughness of syntactic foam: Effect of foam microstructures." Composites Science and Technology 65(11-12) (2005): 1840-1850. 10.1016/j.compscitech.2005.03.012 [4] J. Holbery, D. Houston, "Natural-fiber-reinforced polymer composites applications in automotive." Jom 58(11) (2006): 80-86. DOI 10.1007/s11837-006-0234-2 [5] C. Varga, N. Miskolczi, L. Bartha, G. Lipoczi, "Improving the mechanical properties of glass-fibre-reinforced polyester composites by modification of fibre surface." Materials & Design 31(1) (2010): 185-193. 10.1016/j.matdes.2009.06.034 [6] W.Y. Fu, S.K. Liu, W.H. Fan, H.B. Yang, X.F. Pang, J. Xu, G.T. Zou, "Hollow glass microspheres coated with CoFe2O4 and its microwave absorption property." Journal of Magnetism and Magnetic Materials 316(1) (2007): 54-58. 10.1016/j.jmmm.2007.02.201 [7] N. Gupta, S.E. Zeltmann, V.C. Shunmugasamy, D. Pinisetty, "Applications of Polymer Matrix Syntactic Foams." Jom 66(2) (2014): 245-254. 10.1007/s11837-013-0796-8 [8] S.S. Samsudin, Z.M. Ariff, Z. Zakaria, A.A. Bakar, "Development and characterization of epoxy syntactic foam filled with epoxy hollow spheres." Express Polymer Letters 5(7) (2011): 653-660. 10.3144/expresspolymlett.2011.63 [9] J.S. Huang, L.J. Gibson, "Elastic-Moduli of a Composite of Hollow Spheres in a Matrix." Journal of the Mechanics and Physics of Solids 41(1) (1993): 55-75. Doi 10.1016/0022-5096(93)90063-L [10] L. Wegner, L. Gibson, "Microstructural design of cellular materials—II: Microsandwich foams." Acta metallurgica et materialia 43(4) (1995): 1651-1667. [11] B. Yalcin, Hollow Glass Microspheres in Sheet Molding Compounds, Hollow Glass Microspheres for Plastics, Elastomers, and Adhesives Compounds, Elsevier2015, pp. 123-145. [12] N. Gupta, C.S. Karthikeyan, S. Sankaran, Kishore, "Correlation of processing methodology to the physical and mechanical properties of syntactic foams with and without fibers." Materials Characterization 43(4) (1999): 271-277. Doi 10.1016/S1044-5803(99)00039-X [13] C.S. Karthikeyan, S. Sankaran, M.N.J. Kumar, Kishore, "Processing and compressive strengths of syntactic foams with and without fibrous reinforcements." Journal of Applied Polymer Science 81(2) (2001): 405-411. DOI 10.1002/app.1452 [14] Y. Hu, R.G. Mei, Z.G. An, J.J. Zhang, "Silicon rubber/hollow glass microsphere composites: Influence of broken hollow glass microsphere on mechanical and thermal insulation property." Composites Science and Technology 79 (2013): 64-69. 10.1016/j.compscitech.2013.02.015

Conference: SAMPE 2019 - Charlotte, NC

Publication Date: 2019/05/20

SKU: TP19--1482

Pages: 11

Price: FREE