1ENG 4793: Composite Materials and Processes1Pultrusionver 1ENG 4793: Composite Materials and Processes2Typical Pultrusion ProcessENG 4793: Composite Materials and Processes3Fiber let-offFiber guidesResin impregnationPreformingCuring dieCut-off sawPullerENG 4793: Composite Materials and Processes4Pultrusion EquipmentENG 4793: Composite Materials and Processes5Continuous Fiber ReinforcementENG 4793: Composite Materials and Processes6Hollow Structure Pultrusion Process2ENG 4793: Composite Materials and Processes7RIM (Reaction-Injected Molded) PultrusionENG 4793: Composite Materials and Processes8Exploded View of Pultruded CompositeENG 4793: Composite Materials and Processes9Resins• Thermoset– Polyester– Epoxy– Vinyl ester• Thermoplastics– manyENG 4793: Composite Materials and Processes10Reinforcements• Rovings– continuous–bulk• Continuous strand mat• Chopped strand mat• Surface veilsENG 4793: Composite Materials and Processes11Standard Structures• From small rod and flat sheet to huge I-beams, pultrudedstructurals are available through construction materialsdistributors throughout the country. Composite structurals, withstrengths that allow substitution for steel structurals, fill thedemand for all types of fabricated building structures in mostindustries.ENG 4793: Composite Materials and Processes12Pultruded Products3ENG 4793: Composite Materials and Processes13Pultruded BridgesENG 4793: Composite Materials and Processes14PultrudedI-beamENG 4793: Composite Materials and Processes15Uses of Pultruded Shapes•Construction– Portable work platforms– Sign posts– Lamp posts– Roof trim (Europe)– Gutters– Glazing systems (Europe)– Green house structures– Building panel sections– Sign support posts–Signs– Highway delineator markers• Transportation– Lading bars in trucks and railcars– Kick plates– Trailer jamp posts– Subway contact rail covers– Bus luggage racks– Seating– Flat sheets for refrigerated trucks– Leaf springs• Corrosion Resistant– Bridges and platforms– Floor gratings– Hand rails– Ladder cages– Pipe supports–Stairs– Structural supports– Pipes and tubes– Weir plates– Slide guides– Sucker rods for oil wells– Internal tank supports– Demister blades– Structural shapes– Wet scrubbers for power industry– Cable support trays• Miscellaneous– Heat shields on Xerox copiers– Slats for hog pens– Farm wagons– Pallets in food processing plantsENG 4793: Composite Materials and Processes16Applications for Pultruded Shapes• Consumer/Recreational– Fishing rods– Sail battens– Tent poles– CB antennas– Skate boards– Tool handles– Ski poles– Hockey sticks– Fence posts– Bike flags– Paddle shafts– Bows and arrows– Crossbows– Golf shafts– Flag poles– Pole vault poles– Xylophone bars– Umbrella shafts– Snowmobile track stiffeners• Electrical– Transformer air duct spacersticks– Pole line hardware– Ladders– Bus bar supports– Motor top sticks– Cable support trays– U-shaped motor stouterwedges– Service truck booms– Switch actuators– Fuse tubesENG 4793: Composite Materials and Processes17Mechanical Properties of Pultruded E glass-PolyesterSheetsENG 4793: Composite Materials and Processes18Comparative Properties of Structural MaterialsStructural Property Pultruded Rod & Bar Stainless Steel Low Carbon SteelGlass Content, % by weight 70 - -Flexural Strength, psi 100,000 30,000-35,000 28,000Flexural Modulus, psi x 10560 280 300Tensile Strength, psi 100,000 30,000-35,000 27,000-33,000Tensile Modulus, psi x 10560 280 300Impact Strength, ft.-lb./in. 49 8.5-11 -Thermal Conductivity,BTU/hr./sq. ft./°F/in.5 96-185 260-460Specific Heat, BTU/lb./°F 0.24 0.12 0.10-0.11Rockwell Hardness, scale 80H 90B 72BDielectric Strength,volts/mil>400 - -Specific Gravity (25°C) 2.10 7.92 7.9Density, lb./cu. in. 0.072 0.29 0.29Thermal Coefficient ofExpansion, in./in./°F x 10639-106-84ENG 4793: Composite Materials and Processes19Viscosity change of a thermosetting resin in apultrusion dieENG 4793: Composite Materials and Processes20Temperature distribution along the length of apultrusion dieENG 4793: Composite Materials and Processes21Pull Force vs. TimeENG 4793: Composite Materials and Processes22Pull- Wind ProcessENG 4793: Composite Materials and Processes23Pull - Wind ProcessENG 4793: Composite Materials and Processes24Problems•Fiber wet out• Fiber breakage• Inadequate cure• Too much heat– burning, decomposition• Die jamming– cure to the die5ENG 4793: Composite Materials and Processes25 Pultrusion Evaluation• Investment– Modest capitalequipment– High tooling• Materials– Tailored for pultrusion– Variety growing– New for thermoplastics– Need textile forms• Processing– Slow (< 10 ft/min)– Low labor (automated)– Hazards remote(potentially)• Quality– Smooth surfaces (bothsides)– Voids a problem– Consistent parts– Properties can be high• Products– High volume– Large areas expensive– Constant cross sections– Low cost possibleENG 4793: Composite Materials and