Glass Fibers Presentation - TUM 2024/25 - PDF

Composite Materials and Structure-Property-Relationship 4. Glass Fibers Prof. Dr.-Ing. K. Drechsler Leo Heidemann, M. Sc. Nils Siemen, M. Sc. Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.1. Content 4. Glass Fibers 4.1. Content...

Composite Materials and Structure-Property-Relationship 4. Glass Fibers Prof. Dr.-Ing. K. Drechsler Leo Heidemann, M. Sc. Nils Siemen, M. Sc. Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.1. Content 4. Glass Fibers 4.1. Content 4.2. Introduction to Glass Fibers 4.3. Glass Fiber Manufacture 4.4. Glass Fiber Properties WS 2024/25 | Composite Materials and Structure-Property Relationship 2 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.2. Introduction to Glass Fibers 4.2.1. Historical Perspective of Glass Fibers 4.2.2. General Glass Fiber Applications 4.2.3. Glass Fiber Market Structure 4.2.4. Characteristics of Glass Fibers WS 2024/25 | Composite Materials and Structure-Property Relationship 3 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.2.1. Historical Perspective of Glass Fibers [deutsches-museum.de] 1893: 1937: Glass fiber woven textile First GFRP boat 1665: 1942: Glass threads First GFRP airplane parts 1600BC: Decoration for vessels Today WS 2024/25 | Composite Materials and Structure-Property Relationship 4 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.2.2. General Glass Fiber Applications Insulation Filtration Optical fibers Reinforcement Fig. 2: Fiberglass filter pad [aalfilters.com] Fig. 1: Fiberglass insulation [suburban-insulation.com] Fig. 3: Optical fiber cable Fig. 4: Reinforcement products [ecmag.com] [technologiademateriais.com] WS 2024/25 | Composite Materials and Structure-Property Relationship 5 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.2.3. Glass Fiber Market (1/3) Global roving production 2014 Major producers Roving market: 81% Owens Corning 3B Jushi NEG Yarn market: 19 % Johns Manville CPIC AGY Taishan 13% China 13% North America 58% 16% Europe Fig. 1: Global roving production capacity in 2012; Fig. 2: The eight major producers of fiberglass total: 4.8 million tons WS 2024/25 | Composite Materials and Structure-Property Relationship 6 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.2.3. Glass Fiber Market (2/3) Glass fiber composites 2014 The composite segment accounted for 65% share of the global fiberglass market GFRP are by far the largest group of materials in the composites industry: GFRP: 8.8 million tons, 95% of the total volume of polymer composites CFRP: 53 thousand tons (2014), 100 thousand tons (estimated in 2016) 1% Transport (incl. road vehicles, locomotives, boats and 15% aircraft) Construction (incl. components 35% for wind turbines) 15% Electro / Electronic Sports & Leisure 34% Others Fig. 1: GFRP production in Europe for different application industries in 2016. Total: 1.096 million tons WS 2024/25 | Composite Materials and Structure-Property Relationship 7 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.2.3. Glass Fiber Market (3/3) The European GFRP market In 2014, about 12% of the global GFRP production was done in Europe For 2016, an increase of 2.5% of the European production volume is expected Germany is the largest producer of GFRP in Europe (220,000 tons in 2016) 1400 1195 1200 1132 1096 1065 1058 1049 1020 1043 1069 1015 1010 1000 815 800 600 400 200 0 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016* Fig. 1: GFRP production in Europe since 2005 (in ‘000 tons) (2016* = estimate) WS 2024/25 | Composite Materials and Structure-Property Relationship 8 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.2.4. Characteristics of Glass Fibers (1/3) Thin (5-24 µm) fibers spun out of molten glass Melting temperature E-glass: 650°C high dimensional stability low Young´s Modulus of standard glass fibers* good fire resistance, not inflammable higher heat expansion good moisture and chemical resistance than other fibers (4 … 6.5x10-6 m/m °C)* good strength-to-weight ratio for low priced reinforcement applications low price* (E- and S-Glass): 1-8 €/kg high elongation compared to carbon *compared to carbon and aramid fibers WS 2024/25 | Composite Materials and Structure-Property Relationship 9 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.2.4. Characteristics of Glass Fibers (2/3) Structure of glass fibers Silicon Oxygen Natrium, Kalium, Calcium Fig. 1: Amorphous crystalline structure Fig. 2: Scanning electron microscopy image of glass fiber [Ehrenstein] of glass fiber [Ehrenstein] Glass is amorphous and is sometimes referred to as an undercooled liquid WS 2024/25 | Composite Materials and Structure-Property Relationship 10 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.2.4. Characteristics of Glass Fibers (3/3) Influence of cooling rate Specific volume Frozen sub- Sub-cooled molten mass cooled molten mass molten mass amorphous crystalline Tg Tm Temperature Fig. 1: Influence of cooling rate on crystalline structure of glass Quick cooling below Tc: → No crystallization („frozen liquid / fluid“) → Thermodynamic meta stable → Isotropic WS 2024/25 | Composite Materials and Structure-Property Relationship 11 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.3. Glass Fiber Manufacture 4.3.1. Raw Materials 4.3.2. Process Chain 4.3.3. Manufacturing Routes 4.3.4. Sizing WS 2024/25 | Composite Materials and Structure-Property Relationship 12 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.3.1. Raw Materials (1/2) Silica / Quartz (Si02) Limestone Kaolin + Additives (for special properties) Fig. 1: Crystalline structure of quartz Fig. 2: Quartz Fig. 3: Limestone Fig. 4: Kaolin WS 2024/25 | Composite Materials and Structure-Property Relationship 13 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.3.1. Raw Materials (2/2) Formation of networks within the glass Network builder: e.g. SiO2, B2O3, P2O5 Network converter: e.g. Li2O, Na2O, K2O, Cs2O, CaO => splitting of network Intermediate Oxide: Al2O3, PbO, MgO Network builder Network converter Intermediate Oxide α↓ → TSR ↑ η↓↓ Mech. strength ↑ SiO2 Tg ↑ Li2O Al2O3 Chem. resistance ↑ Mech. strength ↑ α↓ → TSR ↑ η↓ α↓→ TSR ↑ B2O3 Tg ↑ Na2O PbO Tg ↑ Mech. strength ↑ Mech. strength ↑ UV- transparency ↑ Chem. resistance ↑ P2O5 IR-transparency ↓ CaO Chem. resistance ↓ WS 2024/25 | Composite Materials and Structure-Property Relationship 14 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.3.2. Process Chain (1/5): Overview Step 1: Batching before the melting process Step 2: Melting Step 3: Fiberization Batching Step 4: Coating Step 5: Drying/packaging Melting Fiberization Coating Drying Packaging Fig. 1: Process chain of glass fiber manufacturing WS 2024/25 | Composite Materials and Structure-Property Relationship 15 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.3.2. Process Chain (2/5): Batching Batching Silo Melting Fiberization Coating Drying Packaging Fig. 1: Process chain of Glass fiber manufacturing WS 2024/25 | Composite Materials and Structure-Property Relationship 16 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.3.2. Process Chain (3/5): Melting Batching Melting Furnace Fiberization Coating Drying Packaging Fig. 1: Process chain of glass fiber manufacturing WS 2024/25 | Composite Materials and Structure-Property Relationship 17 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.3.2. Process Chain (4/5): Fiberization Batching Melting Bushing Fiberization Coating Drying Packaging Fig. 1: Process chain of glass fiber manufacturing WS 2024/25 | Composite Materials and Structure-Property Relationship 18 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.3.2. Process Chain (5/5): Coating, Drying and Packaging Batching Melting Fiberization Coating Drying Packaging Fig. 1: Process chain of glass fiber manufacturing WS 2024/25 | Composite Materials and Structure-Property Relationship 19 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.3.3. Manufacturing Routes (1/5) Melt Spin Processes Nozzle blowing process Beam drawing process Nozzle pulling process & cylinder drawing process − Marble melt process − Direct melt process − Unit melter (with gas) − Vertical super melter (electrically) WS 2024/25 | Composite Materials and Structure-Property Relationship 20 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.3.3. Manufacturing Routes (2/5) Nozzle pulling process Glass melt Metal blank Bushing Filaments Sizing Fig. 2: Typical Bushing [Koch] Roving Winding Fig. 1: Nozzle pulling process Fig. 3: Bushing in service [Koch] WS 2024/25 | Composite Materials and Structure-Property Relationship 21 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.3.3. Manufacturing Routes (3/5) Nozzle pulling process Temperature profile Fig. 1: Temperature profile of nozzle pulling process [Ehrenstein] Fig. 2: Nozzle pulling process [Campbell] WS 2024/25 | Composite Materials and Structure-Property Relationship 22 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.3.3. Manufacturing Routes (4/5) Nozzle pulling process Marble melt process Batch silos Batch Sorting, grading charging Furnace feeding Melting Refining Remelting in marble bushing Filament formation Sizing application Marble Weighing Strand forming and mixing formation machine Fig. 2: Marble bushing Traversing [Koch] Transport Winding Transport To curing and secondary processing Fig. 1: Marble melt process WS 2024/25 | Composite Materials and Structure-Property Relationship 23 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.3.3. Manufacturing Routes (5/5) Nozzle pulling process Direct melt process Batch silos Batch charging Furnace Melting Refining Forehearths Bushing-Filament formation Weighing and Sizing application mixing Strand formation Fig. 2: Direct melt bushing Traversing [Koch] Transport Winding To curing and secondary processing Fig. 1: Direct melt process WS 2024/25 | Composite Materials and Structure-Property Relationship 24 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.3.4. Sizing Example for bonding to matrix Coupling agent: Aminopropyltriethoxysilane (APTS) Matrix: Epoxy resin Epoxy GFRP OH CH OH CH OH CH APTS Glass + APTS CH2 CH2 CH2 Glass WS 2024/25 | Composite Materials and Structure-Property Relationship 25 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.4. Glass Fiber Properties 4.4.1. Fiber Types and Designation 4.4.2. Comparison to Other Materials 4.4.3. Specific Glass Fiber Applications WS 2024/25 | Composite Materials and Structure-Property Relationship 26 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.4.1. Fiber Types and Designation (1/3) Fiber Description Density [g/cm³] Tensile Strength E-Modulus [GPa] Elongation [%] [MPa] E = electrical (isolator), E-Glass standard reinforcement 2.6 3400 73 < 4.8 for FRP M = modulus, M-Glass high E-modulus and 2.49 7000 125 5.5 tensile strength C = chemically resistant, high amount C-Glass of Boron resulting in 2.52 2400 70 < 4.8 high resistance against acids, oils and solvents R = resistance, S = strength, high tensile strength, R/S2-Glass 2.53 / 2.49 4400 / 4700 86 / 88 4.5 / 5.4 high resistance against temperature and humidity Mechanical High amount properties of alkali, can vary depending 2.68 on fiber producer 3000 and specific types. 73 A-Glass 4.4 used in concrete WS 2024/25 | Composite Materials and Structure-Property Relationship 27 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.4.1. Fiber Types and Designation (2/3) Constituent E ECR C A S R AR SiO2 55.2 58.4 65.0 71.8 65.0 60.0 61.0 Al2O3 14.8 11.0 4 1.0 25.0 25.0 0.5 B2O3 7.3 0.1 5 - - - - ZrO2 - - - - - - 13.0 MgO 3.3 2.2 3.0 3.8 10.0 6.0 0.05 CaO 18.7 22.0 14.0 8.8 - 9.0 5.0 ZnO - 3.0 - - - - - TiO2 - 2.1 - - - - 5.5 Na2O 0.3 - 8.5 13.6 - - - K2O 0.2 0.9 - 0.6 - - 14.0 Li2O - - - - - - - Fe2O3 0.3 0.26 0.3 0.5 - - - F2 0.3 - - - - - - [Stabilizer, network converter] WS 2024/25 | Composite Materials and Structure-Property Relationship 28 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.4.1. Fiber Types and Designation (3/3) Titer: measurement of mass per length 1 Tex = 1 g/1000m Spun fiber: e.g. 51, 102, 204, 408, 816 filaments and more Glass yarns: e.g. EC 9 34 Z 20 GT 07 Type of sizing Number of twists per m twist direction Titer Filament diameter in μ Yarn type (C = continuous) Glass type Glass thread: e.g. EC 9 68 Zx2 S 150 Number of twists per m twist direction of thread Number of twisted yarns twist direction of yarn Roving: e.g. EC 10 – 2400 – K43 (160) Fig. 1: Twist directions of yarns [textillearner.blogspot.com] Titer of spun fiber Type of sizing Titer of Roving WS 2024/25 | Composite Materials and Structure-Property Relationship 29 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.4.2. Comparison to Other Materials (1/2) [MPa] [g/cm³] [MPa] [g/cm³] 8 6000 3000 7 5000 2500 6 4000 5 2000 4 3000 1500 3 2000 1000 2 1000 500 1 0 0 0 Density Tensile strength Specific tensile strength WS 2024/25 | Composite Materials and Structure-Property Relationship 30 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.4.2. Comparison to Other Materials (2/2) [GPa] [g/cm³] [GPa] [g/cm³] 8 500 250 7 6 400 200 5 300 150 4 3 200 100 2 100 50 1 0 0 0 Density Tensile modulus Specific tensile modulus WS 2024/25 | Composite Materials and Structure-Property Relationship 31 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.4.3. Specific Glass Fiber Applications (1/4) Glass-fiber reinforced plastic (GFRP) As endless fibers often used in pultrusion As short fibers common and inexpensive reinforcement of thermoplastics Glass-fiber reinforced concrete (GFRC) Normally AR-glass is used Fig. 1: Pultruded GFRP pipe [compositesworld.com] Fig. 2: GFRC [stylepark.com] WS 2024/25 | Composite Materials and Structure-Property Relationship 32 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.4.3. Specific Glass Fiber Applications (2/4) Reinforcement Boat building Recreation Wind energy Transportation (rail) Aerospace Industrial Construction Automotive Defense WS 2024/25 | Composite Materials and Structure-Property Relationship 33 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.4.3. Specific Glass Fiber Applications (3/4) Example: Wind energy Fig. 1: Glass fiber reinforced blade [w3.windfair.net] Fig. 2: GFRP part WS 2024/25 | Composite Materials and Structure-Property Relationship 34 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich 4.4.3. Specific Glass Fiber Applications (4/4) Example: Reinforced Concrete Fig. 1: Pultrusion of glass-fiber reinforced bars [schoeck.ca] Manufacturing: 1. Pultrusion of the reinforced bars with glass fiber and vinyl ester resin Video: Application of glass-fiber reinforced concrete [ZDF.de] 2. Cutting of ribs in the cured bars 3. Application of final coating WS 2024/25 | Composite Materials and Structure-Property Relationship 35 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich A1 References (1/2) Albrecht, W., Fuchs, W., Kittelmann, W.: Vliesstoffe, Wiley-VCH Verlag GmbH, 2000 Baker, A., Dutton, S., Kelly, D.: Composite Materials for Aircraft Structures, 2nd edition, American Institute of Aeronautics and Astronautics, 2004 Bobeth, W. (Hrsg.): Textile Faserstoffe, Springer Verlag, Berlin, 1993 Campbell, F.C.: Structural Composite Materials, ASM International, 2010 Ehrenstein, G.W.: Faserverbundkunststoffe, 2. Auflage, Carl Hanser Verlag, München, 2006 Fischer, U., Gomeringer, R., Heinzler, M., Kilgus, R., Näher, F., Oesterle, S., Paetzold, H., Stephan, A.: Tabellenbuch Metall, 43. Auflage, Verlag Europa Lehrmittel, 2005 Flemming, M., Ziegmann, G., Roth, S.: Faserverbundbauweisen - Fasern und Matrices, Springer-Verlag, 1995 Green, D.W., Winandy, J.E., Kretschmann, D.E, 1999, Mechanical properties of wood, in: Wood handbook: wood as an engineering material, 1999 WS 2024/25 | Composite Materials and Structure-Property Relationship 36 Chair of Carbon Composites TUM School of Engineering and Design Technical University of Munich A1 References (2/2) Horrocks, A.R., Anand, S.C.: Handbook of Technical Textiles, Woodhead Publishing, 2000 Koch, M., Lupton, D.: Design and Manufacturing of Bushings for Glass Fibre Production, HVG-Colloquium, 2006 Kühnel, M., Witten, E.: Composites Market Report 2014 - Market developments, trends, challenges and opportunities, Carbon Composites e.V., AVK – Industrievereinigung Verstärkte Kunststoffe, 2014 Kühnel, M., Witten, E.: Composites Market Report 2016 - Market developments, trends, outlook and challenges, Carbon Composites e.V., AVK – Industrievereinigung Verstärkte Kunststoffe, 2016 Murphy, J.: Additives for Plastics Handbook, 2nd edition, Elsevier, 2001 Schürmann, H.: Konstruieren mit Faser-Kunststoff-Verbunden, 2. Auflage, Springer Verlag, Berlin, 2007 Witten, E., Kühnel, M.: Composites-Marktbericht 2015 – Marktentwicklungen, Trends, Ausblicke und Herausforderungen, Carbon Composites e.V., AVK – Industrievereinigung Verstärkte Kunststoffe, 2015 Wulfhorst, B.: Textile Fertigungsverfahren, Carl Hanser Verlag, München, 1998 WS 2024/25 | Composite Materials and Structure-Property Relationship 37