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1 UNIVERSITY OF MALAYA UNIVERSITI MALAYA EXAMINATION FOR THE DEGREE OF BACHELOR OF SCIENCE PEPERIKSAAN IJAZAH SARJANA MUDA SAINS ACADEMIC SESSION 2012/2013 : SEMESTER 1 SESI AKADEMIK 2012/2013 : SEMESTER 1 SCES3354 : Composite Materials Bahan Komposit January 2013 Januari 2013 Time : 2 hours Masa : 2 jam INSTRUCTIONS TO CANDIDATES: ARAHAN KEPADA CALON: Answer for new question should start on a new page. Jawapan bagi soalan baru hendaklah dimulakan pada halaman baru. Please look at the marks allocated at the end of each questions and its division. Marks allocated reflect the extend of answer expected. Sila lihat markah yang diperuntukkan di akhir setiap soalan dan bahagiannya. Markah yang diperuntukkan mencerminkan kadar jawapan yang diharapkan. Answer can be written either in Malay or English. Jawapan boleh diberikan sama ada dalam Bahasa Malaysia atau Bahasa Inggeris. (This question paper consists of 4 questions on 7 printed pages) (Kertas ini mengandungi 4 soalan dalam 7 halaman yang dicetak)

2 SCES3354/02 Answer ALL questions. Jawab SEMUA soalan. 1. Give comments on the following statements. Berikan komen terhadap kenyataan berikut. (d) (e) (f) (g) (h) Define composite materials. Takrifkan bahan komposit. When expressing the fibre loading in composite materials, which one is preferable, volume fraction or weight fraction? Apabila menyatakan kandungan gentian dalam bahan komposit, yang mana satu lebih sesuai, pecahan isipadu atau pecahan berat? What are the roles of interface/interphase in fibre reinforced polymer composites? Apakah peranan antara muka / antara fasa dalam bahan komposit polimer diperkuat dengan gentian? What is the advantage of having lower density of fibre in composite materials? Apakah kebaikan mempunyai ketumpatan gentian yang rendah dalam bahan komposit? What is the advantage of having higher tensile strain at break of matrix in composite materials? Apakah kebaikan mempunyai pemanjangan pemutusan yang tinggi pada matriks dalam bahan komposit? What are the differences between thermoset and thermoplastic in terms of recyclability? Apakah perbezaan diantara termoset dan termoplastik dari segi kebolehan untuk diguna semula? Generally, what are the advantages of using thermoset over thermoplastic as matrix in fibre reinforced polymer matrix composites? Secara umumnya, apakah kelebihan menggunakan termoset dibandingkan dengan termoplastik sebagai matriks dalam komposit matriks polimer? Between carbon, glass and aramid fibres, which one is the most suitable for the application as reinforcement for bullet proof vest? Explain. Antara gentian karbon, kaca dan aramid, yang mana satu paling sesuai untuk kegunaan sebagai pengkuat untuk jeket kalis peluru? Terangkan.

3 SCES3354/03 (i) In terms of compatibility or fibre-matrix interfacial adhesion between polyamide 6,6 matrix with glass and Kevlar fibres, which one is better? Explain. Dari segi keserasian atau lekatan antara muka gentian-matriks diantara poliamida 6,6 dengan gentian kaca dan gentian Kevlar, yang mana satu lebih baik? Terangkan. (j) Natural fibre is started to gain attention as reinforcement in technical applications. Gentian asli mula mendapat perhatian sebagai pengkuat dalam kegunaan teknikal. (2 marks each, total 20 marks) (2 markah setiap satu, jumlah 20 markah) 2. Answer the following:- Jawab yang berikut:- The simplest expressions governing the stiffness, Equation (1) and strength, Equation (2) of continuous and uniaxially aligned fibre reinforced composites are given by the following simple rule of mixture (RoM) equations, Ungkapan yang paling mudah menerangkan kekukuhan, Persamaan (1) dan kekuatan, Persamaan (2) untuk komposit diperkuat dengan gentian berterusan dan berarah sejajar diberi oleh peraturan campuran mudah (ROM) berikut, Ec = Ef Vf + Em (1- V f) (1) V + (1- V ) (2) uc = uf f um f where E c, E f, V f, E m, σ uc, σ uf and σ um are modulus of composite, modulus of fibre, volume fraction of fibre, modulus of matrix, tensile strength of composite, tensile strength of fibre and tensile strength of matrix respectively. Can these equations be applied to the discontinuous fibre reinforced composites? Explain. di mana E c, E f, V f, E m, σ uc, σ uf dan σ um adalah modulus komposit, modulus gentian, pecahan isipadu gentian, modulus matriks, kekuatan tegangan komposit, kekuatan tegangan gentian dan kekuatan tegangan matriks masing-masingnya. Bolehkah persamaan ini digunakan untuk komposit gentian tidak selanjar? Terangkan.

4 SCES3354/04 In discontinuous fibre composites, define critical fibre length (L c ). Two equations can be used to calculate L c, Dalam komposit gentian tidak selanjar, takrifkan panjang gentian kritikal (L c ). Dua persamaan boleh digunakan untuk mengira L c, L σuf r τ f c = (3) i L c = E ε f c τ i r f (4) where σ uf, r f, τ i, E f and ε c are tensile strength of fibre, radius of fibre, interfacial shear strength, modulus of fibre and strain of composite respectively. Explain when these equations are used. di mana σ uf, r f, τ i, E f dan ε c adalah kekuatan tegangan gentian, jejari gentian, kekuatan ricih antara muka, modulus gentian dan pemanjangan pemutusan komposit masing-masingnya. Jelaskan bila persamaan ini digunakan. Generally, thermoplastic and thermoset are processed using different types of machinery. Discuss briefly. Secara umumnya, termoplastik dan termoset diproses menggunakan jenis mesin yang berbeza. Bincangkan secara ringkas. (d) Describe briefly, methods for the manufacturing of short fibre composite (SFC) and long fibre composite (LFC) compound or feedstock for injection moulding. Terangkan secara ringkas, kaedah pembuatan kompaun atau bahan untuk pengacuan suntikan, komposit gentian pendek (SFC) dan komposit gentian panjang (LFC). (5 marks each, total 20 marks) (5 markah setiap satu, jumlah 20 markah)

5 SCES354/05 3. Chopped 6 mm fibre was compounded with polymer matrix using twin screw extruder at barrel temperature setting of C. The extrudates were then pelletised and injection moulded to form a tensile and impact test specimens g sample of composite from the central portion of injection moulded test piece was cut. The polymer matrix of the sample was removed by heating the sample in a muffle furnace at the temperature of 700 C and 0.39 g of fibre was collected. In the fibre length distribution (FLD) analysis, 303 fibres with average length of 0.21 mm were found to be shorter than the critical fibre length (L c ) and 197 fibres with average length of 0.47 mm were longer than the L c. Density of the matrix was 1.14 g cm -3. Tensile strength, density and diameter of fibre were 3.4 GPa, 2,600 kg m -3 and 10 μm respectively. From the charpy impact test, the critical strain energy release rate (G c ) of matrix and composite were found to be 3.35 and 9.44 kj m 2 respectively. Matrix shear yield stress of 48 MPa was taken as the fibre-matrix interfacial shear strength ( i ) of the composites. Gentian yang dipotong 6 mm dikompaun dengan matriks polimer menggunakan ekstruder skru berkembar pada suhu C. Ekstrudat kemudiannya dipotong dan dilakukan pengacuan suntikan membentuk spesimen ujian tegangan dan hentaman g sampel komposit dari bahagian tengah sampel ujian suntikan dipotong. Matriks polimer sampel telah dibuang dengan pemanasan sampel dalam relau pada suhu 700 C dan 0.39 g gentian dikumpul. Dalam analisis taburan panjang gentian (FLD), 303 gentian dengan panjang purata 0.21 mm adalah lebih pendek daripada panjang gentian kritikal (L c ) dan 197 gentian dengan panjang purata 0.47 mm adalah lebih panjang daripada L c. Ketumpatan matriks adalah 1.14 g cm 3. Kekuatan tegangan, ketumpatan dan diameter gentian adalah 3.4 GPa, 2,600 kg m 3 dan 10 μm masing-masingnya. Dari ujian hentaman charpy, kadar lepas tenaga terikan kritikal (G c ) matriks dan komposit adalah 3.35 dan 9.44 kj m 2 masing-masingnya. Tegasan ricih matriks yang bernilai 48 MPa telah diambil sebagai kekuatan ricih matriks-gentian antara muka ( i ) bagi komposit. Suggest the name of the possible matrix used in this composite. Give your reasons. Cadangkan nama polimer matrik yang digunakan dalam komposit ini. Berikan alasan. (2 marks/markah) What type of fibre used in this composite? Give your reasons. Apakah jenis gentian yang digunakan dalam komposit ini? Berikan alasan. (2 marks/markah) What is this composite called in terms of continuous- or discontinuousfibre composites and short- or long-fibre composites? Explain. Apakah komposit ini dinamakan dari segi komposit gentian selanjar atau komposit gentian tidak selanjar dan komposit gentian pendek atau komposit gentian panjang? Terangkan. (6 marks/markah)

6 SCES354/06 (d) Calculate the L c. Kirakan L c. (2 marks/markah) (e) Calculate the fibre volume fraction (V f ) of this composite. Kirakan pecahan isipadu gentian (V f ) komposit ini. (4 marks/markah) (f) From all the above data, calculate theoretically the G c value of the composite. Compare this value with the experimental result. If there is any discrepancy, what could lead to the difference? Dari data-data di atas, kirakan secara teori nilai G c komposit. Bandingkan nilai ini dengan nilai hasil percubaan. Jika ada perbezaan, apa yang boleh membawa kepada perbezaan ini? (14 marks/markah) (Note/Nota: 1 MPa = 1 MN m 2 = 1 N mm 2 ; J = N m) (Total = 30 marks) (Total = 30 markah) 4. Answer the following:- Jawab yang berikut:- Processing of thermoplastic polymer matrix composites normally involved two steps, i.e. compounding and moulding. Explain what are compounding and moulding? Pemprosesan komposit matriks polimer termoplastik biasanya melibatkan dua langkah, iaitu mengkompaun dan pengacuan. Terangkan apa yang dimaksudkan dengan mengkompaun dan pengacuan. Although the moulding process can be done directly, explain why compounding is usually not left behind? Walaupun proses pengacuan boleh dilakukan secara terus, jelaskan mengapa mengkompaun biasanya tidak ditinggalkan? List four problems normally associated with the products of injection moulding process. Senaraikan empat masalah yang biasanya dikaitkan dengan produk proses pengacuan suntikan.

7 SCES354/07 (d) A polymer composite manufacturing company received a contract to produce two products, i.e. car bumper and window frame. Manufacturing involve only the final formation stage. If you are the technical personnel incharge and is required requires to handle one of the two products, answer the following:- Sebuah syarikat pembuatan komposit polimer menerima kontrak untuk menghasilkan dua produk, iaitu bumper kereta dan bingkai tingkap. Pembuatan terlibat hanya peringkat pembentukan akhir. Jika anda adalah kakitangan teknikal yang bertanggungjawab dan perlu mengendalikan salah satu daripada dua produk, jawab soalan berikut: - (i) (ii) (iii) (iv) (v) (vi) Choose the product you would like to handle and give your reasons. Pilih produk yang anda ingin kendalikan dan berikan alasan. What is the material normally used for this application? Explain. Apakah bahan yang biasanya digunakan untuk kegunaan ini? Terangkan. In order to improve the properties of the products, name one additive that is normally used. Explain. Untuk meningkatkan sifat-sifat produk, namakan satu bahan tambah yang biasanya digunakan. Terangkan. Suggest a machine that can be employed for the production and explain. Cadangkan satu mesin yang boleh digunakan bagi pengeluaran dan jelaskan. Sketch the schematic diagram of this machine and label at least six of its main components. Give the main function(s) of these components. Lakarkan rajah skematik mesin ini dan label sekurang-kurangnya enam daripada komponen utamanya. Berikan fungsi utama komponen ini. Describe briefly, the procedure in the processing of this product. Terangkan secara ringkas, prosedur dalam pemprosesan produk ini. (22 marks/markah) (Total = 30 marks (Jumlah = 30 markah) **************

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