Wear behaviour of polymeric materials reinforced with man-made fibres: A comprehensive review about fibre volume fraction influence on wear performance

In the mineral processing, mining, oil and gas industries, it is not uncommon to find mechanical components exposed to degradation and wear from slurries. Polymeric matrix composites (PMCs) are considered as potential alternatives to replace metallic materials in such severe environments because of their high strength to weight ratio, ease of production, high wear resistance and good corrosion/chemical resistance. Often, seemingly erratic wear behaviour is observed making preventive maintenance and time-to-failure difficult to manage. A major culprit is the complex physical and chemical interaction with the slurry, such as exposure to high temperatures, high alkalinity, high slurry density, insoluble inorganic contents, high hardness of suspended particles and humidity. It is well understood that the addition of reinforcing fibres greatly improves the stiffness and strength of polymeric matrix composites. However, the effect the reinforcement has on the wear performance is far less established and a framework to analyse the effect of fibre volume fraction is yet to be established. The difficulties in establishing such a framework lay in the multi-factorial contributions and the potential trade-offs with mechanical performance. This makes it much more difficult to isolate clear trends. The objective of the present work is to present a comprehensive review on the influence reinforcing fibres play on wear behaviour of PMCs. The influence of fibre volume fraction on wear performance of polymeric composites reinforced with man-made fibres is presented. The applied load, fibre length, coefficient of friction and chemical treatment of fibres are analysed with respect to wear performance of PMCs. Future trends in the use of fibre-reinforced polymeric composites in wear critical applications are identified. Research gaps in designing composites for wear applications are explained, aiming at motivating future research to address these gaps.

PLASMA POLYMERIZATION ON UNSIZED BASALT FIBRES FOR IMPROVING THE INTERFACIAL STRENGTH WITH POLYMER MATRICES

Basalt fibres are becoming a promising alternative to synthetic fibres as a green reinforcement phase in polymeric matrix composites, showing excellent mechanical, chemical and thermal properties. In this work we synthetized tetravinylsilane (TVS) or a mixture formed by tetravinylsilane and different percentages of oxygen on the surface of unsized basalt fibres through the Plasma-Enhanced Chemical Vapor Deposition (PECVD) technique for improving the fibre/matrix adhesion. Single fibre tensile test proved the effectiveness of the process, without any degradation of the mechanical properties of modified basalt fibres. Finally, through pull out tests, the interfacial properties of basalt fibres were studied, measuring increases up to 80% of the IFSS for modified fibres compared to neat fibres. This result is the consequence of a greater chemical compatibility between the fibres and the matrix, thanks to the presence of a higher number of Si-O-C groups, and of a mechanical interlocking effect promoted by the increased surface roughness of the plasma-modified fibres.

Influence of Rigid Brazilian Natural Fiber Arrangements in Polymer Composites: Energy Absorption and Ballistic Efficiency

Since the mid-2000s, several studies were carried out regarding the development of ballistic resistant materials based on polymeric matrix composites reinforced with natural lignocellulosic fibers (NLFs). The results reported so far are promising and are often comparable to commonly used materials such as KevlarTM, especially when used as an intermediate layer in a multilayer armor system (MAS). However, the most suitable configuration for these polymer composites reinforced with NLFs when subjected to high strain rates still lacks investigation. This work aimed to evaluate four possible arrangements for epoxy matrix composite reinforced with a stiff Brazilian NLF, piassava fiber, regarding energy absorption, and ballistic efficiency. Performance was evaluated against the ballistic impact of high-energy 7.62 mm ammunition. Obtained results were statistically validated by means of analysis of variance (ANOVA) and Tukey’s honest test. Furthermore, the micromechanics associated with the failure of these composites were determined. Energy absorption of the same magnitude as KevlarTM and indentation depth below the limit predicted by NIJ standard were obtained for all conditions.

Research strengths and future perspectives on fiber reclamation of reinforced polymers

Polymers constitute the most employed reinforced matrices to achieve composite materials. Carbon and glass fibers are the reinforcements that are mainly utilized to improve specific properties for both thermoplastics and thermosets creating a new class of materials, which has been applied in several industrial fields. Various products made of fiber reinforced polymers are available on the market and at their own end-of-life, they must be reclaimed and remanufactured, properly, in an ideal recycling circular economy. The aim of this review is to point out the progress on fiber reclaiming from these materials, providing an overview on the most employed strategies and highlighting their main technological limits. Specifically, first, mechanical, thermal and chemical reclaiming processes have been contextualized introducing their peculiarities. Subsequently, the attention has been focalized on the new research trends proposed in the last years showing the direction, where the research is moving to. The processes have been also classified in terms of tensile strength of the reclaimed fibers and in terms of the energy required to be performed. Finally, design for reclaiming and remanufacturing treatments have been also considered pointing out the different approaches that can be pursued as valuable solutions to strengthen the recycling capabilities encouraging as much as possible the recovering of the polymeric matrix composites.

A Brief Review on Additive Manufacturing of Polymeric Composites and Nanocomposites

In this research article, a mini-review study is performed on the additive manufacturing (AM) of the polymeric matrix composites (PMCs) and nanocomposites. In this regard, some methods for manufacturing and important and applied results are briefly introduced and presented. AM of polymeric matrix composites and nanocomposites has attracted great attention and is emerging as it can make extensively customized parts with appreciably modified and improved mechanical properties compared to the unreinforced polymer materials. However, some matters must be addressed containing reduced bonding of reinforcement and matrix, the slip between reinforcement and matrix, lower creep strength, void configurations, high-speed crack propagation, obstruction because of filler inclusion, enhanced curing time, simulation and modeling, and the cost of manufacturing. In this review, some selected and significant results regarding AM or three-dimensional (3D) printing of polymeric matrix composites and nanocomposites are summarized and discuss. In addition, this article discusses the difficulties in preparing composite feedstock filaments and printing issues with nanocomposites and short and continuous fiber composites. It is discussed how to print various thermoplastic composites ranging from amorphous to crystalline polymers. In addition, the analytical and numerical models used for simulating AM, including the Fused deposition modeling (FDM) printing process and estimating the mechanical properties of printed parts, are explained in detail. Particle, fiber, and nanomaterial-reinforced polymer composites are highlighted for their performance. Finally, key limitations are identified in order to stimulate further 3D printing research in the future.

Manufacturing Technology of Some Impact Resistant Materials

In this paper impact resistance is a key parameter for composite materials. Composite structures can experience impact loads either accidentally in the designed life or in an anticipated hostile service environment. That is why the manufacturing technology is very important. For materials manufacture were established: the type of polymer matrix, the types of fabrics and additives which will be used to improve impact resistance and also analysis of mechanical properties of formed composite materials (bending and tensile tests). Knowledge of the mechanical properties of polymeric materials is necessary in all areas of their applicability. Thus, rigidity and mechanical strength are key properties for most applications in which polymeric matrix composites are used.

Optimization of the Tensile Properties of Polymeric Matrix Composites Reinforced with Magnetite Particles by Experimental Design

A full-factorial 33 experiment was used in this study to determine the optimal values of the tensile properties of three composite materials manufactured based on three polymeric resins: Derakane Momentum epoxy vinyl ester based on bisphenol-A (DM-411), polyester based on terephthalic acid (P115-A), and isophthalic polyester (P2000). Such materials were reinforced with magnetite powders at concentrations of 10, 20, and 30 wt %, and the particle sizes were classified with three sieves: #200 (46–75 μm), #325 (26–45 μm), and #500 (0–25 μm). The compounds were manufactured using the hand lay-up method at room temperature in accordance with ASTM D638-14 for M1-type specimens. A tensile test was conducted on a universal Microtest EM2/300/FR machine at a test speed of 5 ± 25 % mm/min using an Epsilon extensometer calibrated in accordance with the ASTM E83 standard at 20 ± 2 °C. The magnetite powders and compound morphology were studied by Scanning Electron Microscopy. The mechanical properties of the compounds and the optimal response found by Analysis of Variance (ANOVA) and Response Surface Methodology (RSM) are also reported. The best response to the mechanical stimuli occurs with the composite material prepared with the epoxy vinyl ester resin DM-411, a concentration of 29.4 % of magnetite (Fe3O4), a particle size of 58.5 microns, and a 200 sieve.

Analytical and numerical study for selecting polymeric matrix composites intended to nuclear applications

This study describes a methodological proposal to select composite materials which are suitable to be employed to manufacture pipes that can properly withstand environments subjected to gamma and neutronic radiation. The methodology is used to select, among many others, the optimal composite material whose properties are used afterwards to simulate several pipe sections by finite element analysis, comparing the results with a well-known nuclear-grade steel, WWER 15Kh2MFAA. The most suitable composite material according to the defined criteria is composed of a phenolic resin matrix reinforced with long boron fibres and exhibit great properties to be used in a nuclear reactor environment: good radiation resistance and mechanical properties with a very low density at low cost. It can be concluded that, in some cases, composite material pipes can be a better option than steel ones. Extending the method to be employed in other industries or with other components could be seen as future works.

Water Absorption in Sisal Fiber Reinforced-Polymeric Matrix Composites: Three-Dimensional Simulations and Experiments

In this work was conducted a theoretical and experimental study of water absorption in polyester matrix composites reinforced with sisal fiber at temperatures of 25, 50 and 70°C. A fiber content 44.6% sisal fibers, and 55.4% polyester matrix were used in the manufacture of the polymer composite. The dimensions of the composite were 20x20x3mm3and 20x20x6mm3. Water absorption tests were conducted by immersion of the samples in a distilled water bath and the water uptake calculated by weight difference of the samples in the dry and wetted condition at different elapsed time. A three-dimensional mathematical model was developed to predict mass transfer during the water absorption inside the parallelepiped solid. Results of water absorption kinetic and moisture content distribution inside the composites showed the more favorable areas which presents delamination problems due the weakness of the fiber-matrix interface and consequently, reduction in the mechanical properties. It was found that the high water bath temperatures accelerate the absorption process and that the water absorption of the sisal reinforced polymer composite with 3 mm of thickness was faster than the with 6 mm of thickness.