Fiberglass

for a report on Materials Engineering 10 at the University of the Philippines, Diliman, College of Engineering

1. Fiberglass

2. History Ancient Egyptians and Phoenicians are among the many civilizations who produced small amounts of coarse glass fibers for decoration 1870 - John Player developed a method for mass-producing glass fibers with a steam jet process. It was used for insulation. 1880 – Hermann Hammesfahr was awarded a patent for a fiberglass cloth interwoven with silk Source: http://chemsrv1.uwsp.edu/fire/FireCD/macrog/mpm/composit/fiber/fibeglas/history.htm

3. History Present 1942 – Owens-Corning were already producing fiberglas and polyester airplane parts 1937 – Ray Greene, working with Owens-Corning produced a sailboat w/ polyester resin/fiberglass composite Source: http://chemsrv1.uwsp.edu/fire/FireCD/macrog/mpm/composit/fiber/fibeglas/history.htm Dale Kleist, working for Corning Glass, accidentally discovered an easy method to create fiberglass: when a jet of compressed air hit molten glass. In 1936, the companies Corning Glass and Owens-Illinois patented the product “Fiberglas” Carlton Ellis of Du Pont was awarded a patent for polyester resin.

4. Present Age Application Pool Window Tanks

5. Present Age Application Car door Cow Insulators Roofing Acoustic wall Submarine Hull

6. Present Age Application Fiber sheets

7. Fiberglass Composite material using resin as matrix and glass fiber as reinforcement

8. Glass Fiber Properties Mechanical Properties similar to glass but different strength value Chemical Stability Susceptible to alkaline solutions and hot water Thermal Properties High heat resistance Electrical Properties insulator Source: http://www.umaine.edu/adhesion/gardner/5502002/glass%20fibers.pdf Skip to Resins Next: Processing

9. Glass Fiber Processing Batching Melting Fiberization Source: http://www.madehow.com/Volume-2/Fiberglass.html#b Coating Drying Raw Materials Packaging Skip to Resin Processing Next: Raw Materials

10. Glass Fiber Processing Raw Materials Major Silica – Glass former Limestone Soda Ash – Lowers mt . pt. w/ limestone Waste glass – a.k.a. cullet Others Calcined Alumina Borax Feldspar Magnesite Etc. Back to Glass Fiber Processing Source: http://www.madehow.com/Volume-2/Fiberglass.html#b Next: Batching

11. Glass Fiber Processing Batching Batching - exact quantities of raw materials are mixed together before being melted. Materials are added to lower the working temperature and add additional properties . Some properties of other components: Al 2 O 3 , CaO , MgO – alkali-resistant B 2 O 3 – increase T melting - T crystalline Source: http://www.compositesworld.com/articles/the-making-of-glass-fiber Back to Glass Fiber Processing

12. Glass Fiber Processing Batching E-glass (Electrical resistance) Contains Al 2 O 3 , CaO , MgO , and B 2 O 3 S-glass (Strength) Contains Al 2 O 3 , MgO , and B 2 O 3 and significantly more SiO 2 C-glass (Chemical resistant) Large content of B 2 O 3 A-glass (Alkali resistant) No content of B 2 O 3 Next: Melting Source: http://www.compositesworld.com/articles/the-making-of-glass-fiber Back to Glass Fiber Processing

13. Glass Fiber Processing Melting Common furnaces has three sections: “Receiver” The batch is melted and uniformly. Bubbles are also removed High temperature (  1400 o C or 2552 o F) Refiner High temperature (  1370 o C or 2500 o F ) Forehearth – beneath this is are bushings Source: http://www.compositesworld.com/articles/the-making-of-glass-fiber Back to Glass Fiber Processing

14. Glass Fiber Processing Melting Three approaches to melting Indirect melt – a.k.a. marble remelt Molten glass is sheared and rolled into marbles w/ diameter of 0.62 inch (15-16 mm), then cooled and packaged to a fiberization process. Useful for outsourcing Large-scale direct melt 8000-100000 tons per year Small-scale direct melt – a.k.a. paramelters 150 to 200 metric tons per year Source: http://www.compositesworld.com/articles/the-making-of-glass-fiber Next: Fiberization Back to Glass Fiber Processing

15. Glass Fiber Processing Fiberization Extrusion Extruded through 200-8000 bushings made of Pt- Rh alloy Bushings are heated electronically to maintain T (  1204 o C/2200 o F) and consequently, glass viscosity and thickness Attenuation Drawing extruded molten glass into filaments using high-speed winder (tangential speed of ~2miles/~3km per minute) High-speed winding applies tension Diameter 4  m to 34  m Source: http://www.compositesworld.com/articles/the-making-of-glass-fiber Back to Glass Fiber Processing *Varying cooling process change the form of the fiber

16. Glass Fiber Processing Fiberization Next: Coating Molten glass flowing through bushings Source: http://www.compositesworld.com/articles/the-making-of-glass-fiber Back to Glass Fiber Processing

17. Glass Fiber Processing Coating A.k.a. Sizing 0.5-2% (w/w) 3 common types: Lubricants – Protect filaments from abrading and breaking Binders – binds resin to glass fiber Coupling agents – increase a ffinity for specific resins Source: http://www.compositesworld.com/articles/the-making-of-glass-fiber Back to Glass Fiber Processing Next: Drying

18. Glass Fiber Processing Drying Back to Glass Fiber Processing Sized filaments are collected The strand is wound onto a drum Dried in an oven Next: Packaging Source: http://www.compositesworld.com/articles/the-making-of-glass-fiber

19. Glass Fiber Processing Drying Collection of sized filaments Strands produce twine-like strands Winders produce balls or “doffs” Used in attenuation Creel produce multi-end products Back to Glass Fiber Processing Next: Packaging Source: http://www.umaine.edu/adhesion/gardner/5502002/glass%20fibers.pdf

20. Glass Fiber Processing Packaging Continuous-filament Rolled in drums and formed into yarns Staple-fiber while cooling, jets of air break filaments into lengths of 8-15 inches Back to Glass Fiber Processing Source: http://www.madehow.com/Volume-2/Fiberglass.html#b

21. Glass Fiber Processing Packaging Chopped fiber Yarns are chopped into short, uniform lengths Glass wool Cooling involves a downward jet of (hot) air, making the fibers fall randomly onto a conveyor belt, forming a fleecy mass Back to Glass Fiber Processing Source: http://www.madehow.com/Volume-2/Fiberglass.html#b Next: Resins

22. Resins Two major types of resin: Polyester and Epoxy . Source: http://www.madehow.com/Volume-2/Fiberglass.html#b Back to Glass Fiber

23. Resins Polyester Permeable to moisture Stable For light-weight objects Cure time ~20-30 min. Lower cost than epoxy Epoxy Moisture resistant Superior reliability, properties, and lifespan Withstands more extreme conditions (acid, heat) Can bond dissimilar materials High tensile strength More flexible Variable cure time Source: http://www.madehow.com/Volume-2/Fiberglass.html#b Next: Processing

24. Resin Processing Source: http://www.madehow.com/Volume-2/Fiberglass.html#b Back to Glass Fiber Processing Essentially polymerization in a large scale Next: Raw Materials Raw Materials Polymerization Processing Purification

25. Resin Processing Raw Materials Polyester Glycols Propylene glycol – low cost, balanced properties Bisphenol A/PG – good chemical resistance, high heat deflection T Acids/anhydrides Unsaturated acids/anhydrides Maleic anhydride – curing site Fumaric acid Phthalic a Saturated acids/anhydrides cid – low cost, hard Isophthalic acid – improved strength and chemical resistance Adipic acid – flexibility, toughness Epoxy Alkaline catalyst(amine or NaOH ) Bisphenol A Epichlorohydrin Solvent Water Source: http://processflowsheets.blogspot.com/2011/05/epoxy-resin-manufacturing-process.html Back to Resin Processing Source: http://www.umaine.edu/adhesion/gardner/5502002/polyester%20resins.pdf

26. Back to Resin Processing Resin Processing Polymerization Polyester Epoxy Source: http://chem.chem.rochester.edu/~chem424/epoxy.htm Next: Purification Source: http://www.umaine.edu/adhesion/gardner/5502002/polyester%20resins.pdf

27. Resin Processing Purification Evaporators and phase separators in the processes separate the final resin from unreacted reactants and unwanted brine. Next: Application Back to Resin Processing

28. Resins Application to Glass Fibers Polyester Hardening catalyst (methyl ethyl ketone peroxide, or MEKP) with a very low ratio (few drops per ounce of resin) Mixed with some wax - wax rises as resin cures Open surface must be facing up Wax is removed afterwards Exothermic Epoxy Varying hardening catalyst type and ratio, depending on type of epoxy (common ratios are 1:1, 3:1, 4:1) Source: http://centralfloridafieros.com/forum/index.php?topic=149.0;wap2 Source: http://centralfloridafieros.com/forum/index.php?topic=149.0;wap2 Next: Fiberglass Back to Resin Processing

29. Source: http://www.youtube.com/watch?v=dEhSaFfaSKg

30. Fiberglass Common types of fiberglass products Roving long and narrow bundle Source: http://www.ce.sc.edu/deptinfo/members/faculty/ray/web1/Ugrad/ECIV%20303/Student%20Presentations/Glass-reinforced%20Plastic.pptx

31. Fiberglass Common types of fiberglass products Chopped Strand Mat Short strands piled randomly  isotropic strength Least expensive Versatile Soaks up the most resin  waterproof Source: http://www.ce.sc.edu/deptinfo/members/faculty/ray/web1/Ugrad/ECIV%20303/Student%20Presentations/Glass-reinforced%20Plastic.pptx

32. Fiberglass Common types of fiberglass products Cloth cross-hatch pattern  bidirectional strength Requires least amount of resin Not waterproof More expensive than mats Great strength but low stiffness Source: http://www.ce.sc.edu/deptinfo/members/faculty/ray/web1/Ugrad/ECIV%20303/Student%20Presentations/Glass-reinforced%20Plastic.pptx

33. Fiberglass Common types of fiberglass products Woven Roving bidirectional interweaving of rovings , thicker than cloth For large applications Uses large strands Source: http://www.ce.sc.edu/deptinfo/members/faculty/ray/web1/Ugrad/ECIV%20303/Student%20Presentations/Glass-reinforced%20Plastic.pptx

34. Fiberglass Common types of fiberglass products Pultruted Pultrusion process: Roving is pulled through a resin to saturate glass. A die shapes the fibers while heat is applied to set the fibers and resin. Finished pieces are cut to desired size. Source: http://www.ce.sc.edu/deptinfo/members/faculty/ray/web1/Ugrad/ECIV%20303/Student%20Presentations/Glass-reinforced%20Plastic.pptx

35. Fiberglass Molding Source: http://www.clubkitclearcote.com/instructions/Hand%20Layup.pdf Plug Mold release agent Gelcoat Lay-up

36. Fiberglass Molding Plug Object with desired shape Can be formed with foams, wood, plaster, etc. Mold Supports glass fibers during resin curing Mold release agent E.g. Polyvinyl alcohol Gelcoat Pigmented resin, harder, more durable finish Followed by a coating of a fiberglass Source: http://centralfloridafieros.com/forum/index.php?topic=149.0;wap2

37. Fiberglass Molding Lay-up Hand lay-up Hand pressure/vacuum/rollers used to ensure even resin application Resin and reinforcements are applied (by hand) to the mold Spray lay-up Resin and reinforcements are sprayed onto the mold Pultrusion Chopped Strand Mat Source: http://www.clubkitclearcote.com/instructions/Hand%20Layup.pdf

38. Fiberglass End