Glass
•The Glass derived from the latin word “Glesum” means transparent,
lustrous substance.
•"A uniform amorphous solid material, usually produced
when a suitably viscous molten material cools very
rapidly.
•Glasses exhibit a glass transition temperature, below which they are
true solids and above which they flow as a very viscous liquid.
•Glass is a state of matter not a substance.
•Glass is a hard, brittle, and usually transparent material.
•Glass is often referred to as a supercooled liquid in that it has no
crystallisation or melting point.
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Glass
Glass is made by heating together ingredients at a very high
temperature to form a liquid, then cooling this liquid to room
temperature. Through cooling no discontinuous changes take place in
the glass melt; it gets stiffer and stiffer until it is rigid like a solid, yet
maintains the internal structure of a liquid. In a liquid the atoms are
joined to one other in a random structure rather than a regular
extended three- dimensional pattern.
Common glass is generally composed of a silicate (such as silicon
oxide) combined with an alkali and sometimes other substances.
These are inorganic, room-temperature glasses consisting of a three
dimensional network of silicon and oxygen of formula SiO
2, with various
inorganic additives which help determine their physical properties.
Glass Fiber
A Glass fibre or Fibre glass can be defined as
•“A material consisting of extremely fine filaments of glass
that are combined in yarn and woven into fabrics, used
in masses as a thermal and acoustical insulator, or
embedded in various resins to make boat hulls, fishing
rods, and the like.”
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Glass Fiber
•Fiberglass materials are popular for their
attributes of high strength compared to
relatively light weight.
•Fiberglass really is made of glass, similar
to windows or the drinking glasses. The
glass is heated until it is molten, then it is
forced through superfine holes, creating
glass filaments that are very thin – so thin
they are better measured in microns.
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HISTORY
•Glass has been made for at least 6000 years. The drawing of glass
into fine filaments is an ancient technology, older than the
technology of glass blowing.
•In the 1700s, Réaumur recognised that glass could be finely spun
into fibre that was sufficiently pliable to be woven into textiles.
Napoleon’s funeral coffin was decorated with glass fibre textiles.
•By the 1800s, luxury brocades were manufactured by co-weaving
glass with silk, and at the Columbia Exhibition of 1893, Edward
Libbey of Toledo exhibited dresses, ties and lamp-shades woven
from glass fibre.
•The scientific basis for the development of the modern reinforcing
glass fibre stems from the work of Griffiths, who used fibre formation
to validate his theories on the strength of solids.
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Glass Structure
•The basic component of glass fibers is silica (silicon dioxide SiO
2) derived
from ordinary sand.
•Sand consists of an irregular network of silicon atoms held together by Si—
O—Si bonds.
•In its crystalline form its basic structure is that of a tetrahedron, with four
oxygen atoms surrounding a central silicon atom.
•It has no true melting point but softens up to 2000°C, where it starts to
degrade.
•It is usual to introduce impurities into the glass in the form of other materials
to lower its working temperature. These materials also impart various other
properties to the glass which may be beneficial in different applications.
•In its pure form it exists as a polymer, (SiO
2)
n.
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Difference between Glass and Fibreglass
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Instead, in nature SiO
2 is often found as a crystalline solid, with a structure like you see on your right. Every silicon atom is bonded four
oxygen atoms, tetrahedrally, of course; and every oxygen atom is bonded to two silicon atoms. When SiO
2 is in this crystalline form we call it
silica. You've seen silica before. When you find big honkin' crystals of it we call it quartz. When we have a lot of little tiny crystals of it, we call
it sand.
But this silica isn't glass. We have to do something to it first to make it into glass. We have to heat it up until it melts, and then cool it down
really fast. When it melts, the silicon and oxygen atoms break out of their crystal structure.
Glass: If we cool it down fast enough, the atoms of the silica will be stopped in their tracks. They won't have time to line up and becomes
brittle glass.
Fibreglass: If we cooled it down slowly, the atoms would slowly line back up into their crystalline arrangement as they slowed down.
(Remember, heat is really just the
random motion of atoms and molecules. Hot atoms move a lot, cold atoms move very little.)
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Glass Fibre Compositions
The addition of other oxides of metals such as sodium,
calcium, aluminum, magnesium, etc., to silica serves to
1.Alter the network structure and the bonding,
2.Production efficiency (melting and fiberization)
–a reduction in viscosity which makes for easy processing.
3.End product performance.
–Different formulas affect the mechanical, electrical, chemical,
optical, and thermal properties of the glasses that are produced.
4.Cost
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Glass Fibre Compositions
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Fibre Glass Compositions
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Type Description
Silica Increase strength and acid resistance
Na
2O and CaO
makes the mixture more fluid, reduce durability
poor electrical properties.
B
2O
3 expands less on heating
MgO slow down the rate at which the glass crystallizes.
Al
2O
3, ZnO increase durability, improve moisture resistance
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Types of Glass Fibre
Type Description
A Glass
Contains 72% slilica. High Alkali Glass containing (25% Soda and
lime). Is transparent, easily formed and most suitable for window
glass. Poor resistance to heat (500– 600 °C). Used for windows,
containers, light bulbs, tableware.
C Glass
Chemical glass—Sodium borosilicate glass (alkali-lime glass) with
high boron oxide content, improved durability, making it preferred
composition for applications requiring corrosion resistance. Used for
glass staple fibers possesses
D glass
Borosilicate glasses with improved dielectric strength and low density,
developed for improved electrical performance.
E Glass
An electrically resistant glass fibre.
Alumina-calcium-borosilicate glasses. Constitutes the majority of glass
fibre production. Used in glass reinforced plastics as general purpose
fibres where strength and high electrical resistivity are required.
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Types of Glass Fibre
Type Description
ECR Glass
Calcium aluminosilicate glasses
Modified “E” glass having superior long term resistance to
strain crack corrosion in acid conditions.
AR Glass
High Quality Alkali resistant glasses composed of alkali
zirconium silicates used in cement substrates and concrete.
R Glass
Calcium aluminosilicate glasses High-strength, high-modulus
glass at a lower cost than “S”.
S & S2
Glass Magnesium aluminosilicate glasses (40% higher than E-glass)
developed for aerospace applications.
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Glass Fibre:
Manufacturing Process
1.Direct Melt Process
2.Marble Melt
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Manufacturing Process
•The fibre manufacturing process has effectively
two variants.
1.One involves the preparation of marbles,
which are remelted in the fiberisation stage.
2.The other uses the direct melting route, in
which a furnace is continuously charged with
raw materials which are melted and refined as
that glass reaches the forehearth above a set of
platinum–rhodium bushings from which the
fibres are drawn.
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Direct Melt Process
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Manufacturing Process
Step 1: Batching
•In the initial stage of glass manufacture,
materials must be carefully weighed in
exact quantities and thoroughly mixed
(batched). More than half the mix is silica
sand, the basic building block of any glass.
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Manufacturing Process
Step 2: Melting
•From the batch house, pneumatic conveyor sends the mixture to a
high temperature (≈1400ºC) furnace for melting. The furnace is
typically divided into three sections, with channels that aid glass
flow.
•The first section receives the batch, where melting occurs and
uniformity is increased, including removal of bubbles.
•The temperature is so high that the sand and other ingredients
dissolve into molten glass.
•The molten glass then flows into the refiner, where its temperature is
reduced to 1370ºC .
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Manufacturing Process
Step 3: Fiberization
•Glass fiber formation, or fiberization, involves a combination of extrusion
and attenuation.
•In extrusion, the molten glass passes out of the forehearth through a
bushing made of an erosion-resistant platinum alloy with very fine orifices,
in thousands. Bushing plates are heated electronically, and their
temperature is precisely controlled to maintain a constant glass viscosity.
Water jets cool the filaments as they exit the bushing at roughly 1204ºC .
•Attenuation is “the process of mechanically drawing the extruded streams
of molten glass into fibrous elements” called filaments, with a diameter
ranging from 4 μm to 34 μm (one-tenth the diameter of a human hair).
•A high-speed winder catches the molten streams and, because it revolves
at a circumferential speed of ~2 miles/~3 km per minute (much faster than
the molten glass exits the bushings), tension is applied, drawing them into
thin filaments.
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Manufacturing Process
Step 4: Coating
•In the final stage, a chemical coating, or size, is applied.
•Size is typically added at 0.5 to 2.0 percent by weight and may
include lubricants, binders and/or coupling agents. The lubricants
help to protect the filaments from abrading and breaking as they are
collected and wound into forming packages and, later, when they
are processed by weavers or other converters into fabrics or other
reinforcement forms.
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Manufacturing Process
Step 5: Drying/packaging
•Finally, the drawn, sized filaments are collected
together into a bundle, forming a glass strand
composed of 51 to 1,624 filaments. The strand
is wound onto a drum into a forming package
that resembles a spool of thread. The forming
packages, still wet from water cooling and sizing,
are then dried in an oven, and afterward they
are ready to be palletized and shipped or further
processed into chopped fiber, roving or yarn.
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Marble Melt Process
The Marble melt process can be used to form special purpose, for example high strength
fibres. In this process the raw mateirals are melted, and solid glass marbles usually 2 to 3 cm
(0.8 to 1.2 in) in dia are formed from the melt. The marbels are remelted (at the same or at a
different location) and formed into glass fibers.
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Glass Fibre Forms
•Wide ranges of fibre forms (yarn sizes and weave patterns) provide huge
number of design potential allowing the end user to choose the best
combination for material performance, economics and flexibility.
•Glass fibers forms can be divided into two major groups according to their
geometry:
1.Continuous fibers used in yarns and textiles, and
2.The discontinuous (short) fibers used as batts, blankets, or boards for
insulation and filtration.
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Glass Fibre Forms
•Glass fibres are used in different forms for various applications or
composite products.
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Fibre Glass
Composite Products Manufacturing Process
1.Pultrusion Process
2.Gun Roving Process
3.Filament Winding Process
4.Molding Process
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Pultrusion
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In the pultrusion process
the reinforcement glass
fibers are impregnated with
resin (binder), and pulled
through a heated stationary
die for making constant
structural shapes.
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Gun Rovnig
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Filament Winding
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Molding
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PROPERTIES
The versatility of glass as a fiber makes it unique industrial textile
material.
Dimensional Stability: glass fiber is a dimensionally stable
engineering material. Glass fiber does not stretch or shrink after
exposure to extremely high or low temperatures. The maximum
elongation for “E” glass at break is 4.8% with a 100% elastic recovery
when stressed close to its point of rupture.
Moisture Resistance: Glass fibers do not absorb moisture or change
physically or chemically when exposed to water.
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PROPERTIES
High Strength: The high strength- to-weight ratio of glass
fiber makes it a superior material in applications where high
strength and minimum weight are required. In textile form,
this strength can be unidirectional or bidirectional, allowing
flexibility in design and cost.
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PROPERTIES
Fire Resistance: glass fiber is an inorganic material and will not burn or
support combustion. It retains approximately 25% of its initial strength at
1000°F (540°C) .
Chemical Resistance:
Most chemicals have little or no effect on glass fiber. The inorganic glass textile
fibers will not mildew or deteriorate. Glass fibers are affected by hydrofluoric,
hot phosphoric acids and strong alkaline substances.
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PROPERTIES
Electrical Properties:
Glass fiber is an excellent material for electrical insulation.
The combination of properties such as low moisture
absorption, high strength, heat resistance and low dielectric
constant makes fiber glass fabrics ideal as a reinforcement
for printed circuit boards and insulating varnishes.
Thermal Conductivity:
A low coefficient of thermal expansion combined with low
thermal conductivity properties makes glass fabric a
dimensionally stable material that rapidly dissipates heat as
compared to asbestos and organic fibers.
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APPLICATIONS
Automotive Market
•The automobile industry is one of the largest users of glass fibre.
Polymer matrix composites containing glass fibers are used to make
external body panels, bumper beams, pultruded body panels and air
ducts, engine components, etc. Parts made are much lighter than
metallic ones, making the automobile more fuel efficient.
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APPLICATIONS
Aerospace Market
•Glass fiber reinforced composites are used to make aircraft parts
such as wings, helicopter rotor blades, engine ducts etc. glass fiber
has a relatively low elastic modulus. Hence it is more common to
use glass fiber reinforced polymer composites in the interior of an
airplane rather than in primary structural parts.
•The radar transparency characteristics of glass has given it some
key uses in the radar evading stealth technologies.
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APPLICATIONS
Marine Market
•Sailing boats and hulls and decks of commercial fishing boats and
military mine hunters are frequently made of glass fiber reinforced
polymers. Glass fiber reinforced polyester is commonly used in
making boats of all sizes.
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Kayaks made of fiberglass
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APPLICATIONS
Civil Construction
•Typical applications include the use of glass fibers in polymeric resins
for paneling, bathtubs and shower stalls, doors, windows etc. glass
fibers are also used as reinforcement in a variety of house hold items
such as paper, tapes, lampshades etc. Some special alkali resistant
glass fibers have been developed for reinforcement of cement and
concrete. Commonly steel bars are used for such purposes.
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APPLICATIONS
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APPLICATIONS
•Civil Construction: Insulation
•Heat loss from a house
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APPLICATIONS
Sporting Goods
•The sporting goods industry was one of the first to make
use of glass fiber reinforced composites. Examples
include bicycle frames, tennis, rackets, golf club shafts,
cricket bats, skis, etc
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APPLICATIONS
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APPLICATIONS
Electrical/Electronic Market
•Glass fibers are used extensively in printed
circuit boards, industrial circuit breakers,
conduits for power cables. etc
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