Handbook of Composites from Renewable Materials, Design and Manufacturing

Author: Vijay Kumar Thakur   Manju Kumari Thakur   Michael R. Kessler  

Publisher: John Wiley & Sons Inc‎

Publication year: 2017

E-ISBN: 9781119224297

P-ISBN(Paperback): 9781119223658

Subject: O6 Chemistry

Language: ENG

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Description

The Handbook of Composites From Renewable Materials comprises a set of 8 individual volumes that brings an interdisciplinary perspective to accomplish a more detailed understanding of the interplay between the synthesis, structure, characterization, processing, applications and performance of these advanced materials. The handbook covers a multitude of natural polymers/ reinforcement/ fillers and biodegradable materials. Together, the 8 volumes total at least 5000 pages and offers a unique publication.

This 2nd volume of the Handbook is solely focused on the Design and Manufacturing of renewable materials. Some of the important topics include but not limited to: design and manufacturing of high performance green composites; manufacturing of high performance biomass-based polyesters by rheological approach; components design of fibrous composite materials; design and manufacturing of bio-based sandwich structures; design and manufacture of biodegradable products from renewable resources; manufacturing and characterization of quicklime filled metal alloy composites for single row deep groove ball bearing; manufacturing  of composites from chicken feathers and poly (vinyl chloride); production of porous carbons from resorcinol-formaldehyde gels: applications; composites using agricultural wastes; manufacturing of rice wastes-based natural fiber polymer composites from thermosetting vs. thermoplastic matrices; thermoplastic polymeric composites; natural fiber reinforced PLA composites; rigid closed-cell PUR foams containing polyols derived from renewable resources; preparation and application of the composite from alginate; recent developments in biocomposites of bombyx mori silk fibroin; design and manufacturing of natural fiber/ synthetic fiber reinforced polymer hybrid composites; natural fibre composite strengthening solution for structural beam component for enhanced flexural strength; high pressure resin transfer molding of epoxy resins from renewable sources; cork based structural composites; the use of wheat straw as an agricultural waste in composites for semi-structural applications and design/ manufacturing of sustainable composites.

Chapter

1.3 Curing of Bio-Based Epoxy Resins – an Ecological Approach

1.4 Natural Fibers

1.4.1 Mechanical Performance of Bast Fibers

1.5 Processing Routes

1.6 Applications and Requirements

1.7 Concluding Remarks

Acknowledgement

References

2 Manufacturing of High Performance Biomass-Based Polyesters by Rheological Approach

2.1 Introduction

2.2 Linear Viscoelastic Properties

2.2.1 Rheological Parameters

2.2.2 Effect of Degradation

2.3 Enhancement of Crystallization Rate

2.4 Rheological Modification for Marked Melt Elasticity

2.4.1 Addition of Flexible Nanofiber

2.4.2 Addition of Critical Gel

2.5 Conclusion

Acknowledgments

References

3 Design of Fibrous Composite Materials for Saving Energy

3.1 Introduction

3.1.1 Energy and Power Efficiency

3.1.2 Energy Losses

3.2 Microthermomechanical Fiber Composites Behavior

3.2.1 Challenges of Numerical Simulation of Fibrous Composite Materials

3.2.1.1 Large Gradients of Physical Fields

3.2.1.2 Material Micro-Structure

3.2.1.3 Interaction

3.2.1.4 Interfacial Conditions

3.2.1.5 3D Problem

3.2.2 Computational Methods for Fibrous Composite Materials

3.2.3 Meshless Computational Methods

3.2.4 Method of Continuous Source Functions

3.2.4.1 Source Functions

3.2.4.2 Model Description

3.2.5 Numerical Results of MCSF – Microthermomechanical Response

3.2.5.1 Single Fiber in Matrix

3.2.5.2 Fiber Patch of Regularly Distributed Fibers

3.2.5.3 Interaction of Two Overlapping Fibers

3.2.6 Numerical Simulation of Wave Propagation and Experimental Testing

3.3 Industrial Applications — Case Studies

3.3.1 Printing Industry Application

3.3.1.1 Vibrations and Component Joints Accuracy

3.3.1.2 Use of Composite Structures for Flexoprinting

3.3.1.3 Discussion

3.3.2 Aerospace Industry Application

3.3.2.1 Composite Materials in Plane Viper SD-4

3.3.2.2 Discussion and Potential of Fibrous Composite Usage

3.3.3 Mechanical Engineering Industry Application

3.3.3.1 Nanostructured Coating and Microstructuring of Cutting Edge

3.3.3.2 Nanocomposite Coating

3.3.3.3 Discussion

3.4 Conclusions

References

4 Design and Manufacturing of Bio-Based Sandwich Structures

4.1 Introduction

4.2 Bio-Based Core Materials

4.2.1 Plant-Based Cores

4.2.2 Biopolymer-Based Foam Cores

4.2.3 Biopolymer-Based Cores

4.3 Manufacture of Sandwich Panels

4.4 Recent Studies on Bio-Based Sandwich Panels

4.5 Applications of Bio-Based Sandwich Panels

4.6 Conclusions

References

5 Design and Manufacture of Biodegradable Products from Renewable Resources

5.1 Introduction

5.2 Materials and Processes for Biodegradable Composites

5.2.1 Nature of Biodegradable Polymers

5.2.2 Processing of Thermoplastic Starch Bulk Material

5.2.3 Processing of Thermoplastic Starch Films

5.2.4 Biodegradable Reinforcement

5.2.5 Biodegradable Bulk Composites

5.2.6 Biodegradable Film Composites

5.3 Performance of Biodegradable Composites Under Service Conditions

5.3.1 Thermal Stability

5.3.2 Water Uptake

5.3.3 Biodegradation

5.4 Case Studies

5.4.1 Use of Biodegradable Composites in the Transport Industry, with Special Reference to Motorcar Panels

5.4.1.1 Introduction

5.4.1.2 Materials and Manufacturing Processes for Interior Panels

5.4.1.3 Performance Indices of Interior Panels

5.4.2 Use of Biodegradable Composites in the Packaging Industry, with Special Reference to Disposable Flexible Food Packaging

5.4.2.1 Introduction

5.4.2.2 Flexible Packaging Materials

5.4.3 Use of Biodegradable Composites in Biomedical Applications, with Special Reference to Dissolvable Bone Plates

5.4.3.1 Introduction

5.4.3.2 Comparison of Candidate Bone Fixation Materials

References

6 Manufacturing and Characterization of Quicklime (CaO) Filled ZA-27 Metal Alloy Composites for Single-Row Deep Groove Ball Bearing

6.1 Introduction

6.2 Experimental Details

6.2.1 Raw Materials

6.2.2 Fabrication of Composites

6.2.3 Physical and Mechanical Characterization

6.2.3.1 Density and Void Contents

6.2.3.2 Hardness

6.2.3.3 Compressive Strength

6.2.3.4 Impact Strength

6.2.3.5 Bending Strength

6.2.4 Fracture Toughness Analysis

6.2.5 Contact Stress Analysis of the CaO Particulates Filled ZA-27 Alloy Composites Using FEM Element Type and Meshing Procedure

6.2.5.1 Contact Model

6.2.5.2 Boundary Condition and Application of Load

6.2.5.3 Structural Analysis

6.2.5.4 Numerical Modeling

6.2.5.5 Mathematical Modeling

6.2.6 Hardness Analysis of the CaO Particulates Filled ZA-27 Alloy Composites Using FEM

6.2.6.1 Finite Element Model

6.2.6.2 Element Type and Meshing

6.2.6.3 Material Properties and Boundary Condition

6.2.6.4 Mathematical Modeling

6.3 Result and Discussions

6.3.1 Effect of Void Content on CaO Particulates Filled ZA-27 Alloy Composites

6.3.2 Effect of Hardness on CaO Particulates Filled ZA-27 Alloy Composites

6.3.3 Effect of Compressive Strength on CaO Particulates Filled ZA-27 Alloy Composites

6.3.4 Effect of Flexural Strength on CaO Particulates Filled ZA-27 Alloy Composites

6.3.5 Effect of Impact Strength on CaO Particulates Filled ZA-27 Aalloy Composites

6.3.6 Effect of Fracture Toughness on CaO Filled ZA-27 Alloy Composites

6.3.7 Fractography of CaO Particulates Filled ZA-27 Alloy Composites After Fracture Test

6.3.8 Effect of Hardness and Contact Stress and Deformation of CaO Particulates Filled ZA-27 Alloy Composites

6.4 Conclusions

Acknowledgement

References

7 Manufacturing of Composites from Chicken Feathers and Polyvinyl Chloride (PVC)

7.1 Introduction

7.2 Experimental

7.3 Results and Discussion

7.3.1 Processability

7.3.2 Thermal Properties

7.3.3 Dynamic Mechanical Analysis (DMA)

7.3.4 Scanning Electron Microscopy (SEM)

7.4 Conclusions

Acknowledgments

References

8 Production of Porous Carbons from Resorcinol-Formaldehyde Gels: Applications

8.1 Introduction

8.2 Synthesis of Aerogels

8.2.1 Synthesis of Resorcinol-Formaldehyde Gels

8.3 Polymeric Gels from Renewable Raw Materials

8.4 Carbonization of Polymeric Resins

8.5 Drying the Polymeric Gel

8.5.1 Supercritical and Cryogenic Drying

8.5.2 Structure and Properties of Xero-, Cryo- and Supercritical Gels

8.6 Gel Stabilization

8.6.1 The Use of Surfactants During the Synthesis of Resins

8.6.2 The Use of Polyelectrolytes as Pore Stabilizer During the Synthesis of Resins

8.7 Pyrolysis of R-F Resins

8.8 Applications of the Gels

8.8.1 Resorcinol-Formaldehyde-Based Porous Carbon as Heterogeneous Catalyst for Biodiesel Production and Fischer Reaction

8.8.2 Porous Carbon Obtained from R-F Resins as an Electrode Material for Supercapacitors

8.9 Conclusions

References

9 Composites Using Agricultural Wastes

9.1 Introduction

9.2 Natural Fibers Classification

9.3 Types of Plant Fibers

9.3.1 Natural Fiber Materials

9.3.1.1 Lignocelluloses Structure

9.3.1.2 Mechanical Properties of Natural Fibers

9.3.2 Straw as a Reinforcement Material

9.3.2.1 The Fractions of Straw

9.3.2.2 The Morphology of Straw

9.3.2.3 Chemical Composition of the Straw

9.4 Composite Mechanical Properties

9.4.1 Theoretical Principles of Fiber Reinforcement

9.4.2 Concept of Critical Volume Fraction

9.4.3 Critical Fiber Aspect Ratio

9.5 Industry Process of Some Biocomposites Using Agricultural Wastes

9.5.1 Earth Bricks

9.5.1.1 Introduction

9.5.1.2 Materials

9.5.1.3 Bricks Preparation

9.5.1.4 Microstructure of Earth Bricks

9.5.1.5 Bricks Properties

9.5.2 Earth Plaster Composites for Straw Bale Buildings

9.5.2.1 Materials

9.5.2.2 Composite Properties

9.5.3 Embankments and Dams

References

10 Manufacturing of Rice Waste-Based Natural Fiber Polymer Composites from Thermosetting vs. Thermoplastic Matrices

10.1 General Introduction

10.2 Scope Survey of Agro-Based NFPC Composites

10.2.1 Factors Affecting the Properties of NFPC

10.2.1.1 Thermosetting Polymers

10.2.1.2 Thermoplastic Polymers

10.2.2 Improving the Compatibility Between Matrix and Fiber

10.2.2.1 Mechanical Pretreatment

10.2.2.2 Physical Pretreatment

10.2.2.3 Chemical Pretreatment

10.2.2.4 Biological Pretreatment

10.3 Optimizing the Conditions for Production of High Performance Natural Fiber Polymer Composites

10.3.1 Material and Methods

10.3.1.1 Natural Fibers Component

10.3.1.2 Matrices Polymers

10.3.1.3 NFPC Preparation and Tests

10.3.2 Results & Discussion

10.3.2.1 Evaluating the Rice Waste-Polyester-Based NFPC

10.3.2.2 Comparisons Based on Evaluating Rice Wastes-Polypropylene-Based NFPC and Rice Wastes-PS –Based NFPC

10.3.3 Conclusions

Acknowledgment

References

11 Thermoplastic Polymeric Composites and Polymers: Their Potential in a Dialogue Between Art and Technology

11.1 Introduction

11.2 “Organic Beauty” in 1998

11.3 “Organic Beauty” and Other Sculptures in 2014

11.4 Laboratory Experiments

11.5 Final Remarks

Acknowledgments

References

12 Natural Fiber Reinforced PLA Composites: Effect of Shape of Fiber Elements on Properties of Composites

12.1 Introduction

12.2 Natural Reinforcers

12.2.1 Chemical and Anatomical Structure of Plants

12.2.2 Wood Elements as Reinforcers

12.2.3 Annual Plants for Continuous Fibers

12.3 Element Morphology

12.3.1 Producing of Wood Elements – Size Reduction

12.3.1.1 Size Reduction by Mechanical Processes – Production of Particle Elements

12.3.1.2 Size Reduction by Thermo-Mechanical Process – Production of Fiber Elements

12.3.1.3 Wood Flour

12.3.2 Characterizing the Shape of Elements

12.3.2.1 Sieve Analysis

12.3.2.2 Image Analysis

12.3.3 Wood-Reinforced Polymer Composites – Effect of Element Morphology

12.3.4 Conclusion

12.4 Continuous Fiber Reinforced PLA Composite

References

13 Rigid Closed-Cell PUR Foams Containing Polyols Derived from Renewable Resources: The Effect of Polymer Composition, Foam Density, and Organoclay Filler on Their Mechanical Properties

13.1 Introduction

13.2 Experimental

13.2.1 Materials

13.2.2 Preparation of PUR Foams and Monolithic Polymers

13.2.3 Foam Morphology

13.2.4 X-ray Diffraction Analysis

13.2.5 Specimens and Tests

13.3 Modeling the Mechanical Properties of Foams

13.3.1 Continuum Models

13.3.2 Strut-Based Models

13.4 Results and Discussion

13.4.1 Test Results of Neat Monolithic and Foamed PUR

13.4.2 Modeling the Properties of Neat Foams

13.4.3 The Effect of Clay Filler

13.5 Conclusions

Acknowledgement

References

14 Preparation and Application of the Composite from Alginate

14.1 Introduction

14. 2 Composites from Alginate and Natural Polymers

14.2.1 Composites from Alginate and Chitosan

14.2.2 Composites from Alginate and Collagen

14.2.3 Composites from Alginate and Gelatin

14.2.4 Composites from Alginate and Hyaluronic Acid

14.2.5 Composites from Alginate and Cellulose

14.2.6 Composites from Alginate and Heparin

14.3 Composites from Alginate and Synthetic Polymers

14.3.1 Composites from Alginate and Polyurethane

14.3.2 Composites from Alginate and Poly (Vinyl Alcohol)

14.3.3 Composites from Alginate and Poly(γ-Glutamic Acid)

14.4 Composites from Alginate and Biomacromolecules

14.4.1 Composites from Alginate and Protein

14.4.1.1 Composites from Alginate and Silk Fibroin

14.4.1.2 Composites from Alginate and Silk Sericin

14.4.1.3 Composites from Alginate and Soy Protein

14.4.2 Composites from Alginate and Peptide

14.5 Composites from Alginate and Inorganic Components

14.5.1 Composites from Alginate and Hydroxyapatite

14.5.2 Composites from Alginate and Silica

14.5.3 Composites from Alginate and Silver Nanoparticles

14.5.4 Composites from Alginate and Titanium Dioxide Nanoparticles

14.5.5 Composites from Alginate and Fe3 O4

14.6 Composites from Alginate and Carbon Materials

14.6.1 Composites from Alginate and Carbon Nanotubes

14.6.2 Composites from Alginate and Graphene Oxide

14.7 Composites from Alginate and Clays

References

15 Recent Developments in Biocomposites of Bombyx mori Silk Fibroin

15.1 Introduction

15.2 History of B. mori Silk

15.3 Chemical Composition of B. mori Silk

15.3.1 Fibroin

15.3.2 Sericin

15.3.3 Mineral Matters

15.3.4 Fatty and Waxy Matters

15.4 Properties of B. mori Silk

15.4.1 Appearance

15.4.2 Dimensions

15.4.3 Specific Gravity

15.4.4 Tensile Properties

15.4.5 Hygroscopicity

15.4.6 Thermal Properties

15.4.7 UV Resistance

15.4.8 Other Properties

15.4.9 Chemical Properties of B. mori Silk

15.4.9.1 Effect of Water

15.4.9.2 Effect of Acids

15.4.9.3 Effect of Alkalis

15.4.9.4 Effect of Salts

15.4.9.5 Effect of Oxidizing Agents

15.5 Extraction of Silk Fibroin by Degumming Process

15.6 Regenerated Fibroin Solution

15.7 Silk Fibroin Hydrogels

15.8 Methods of SF-Based Biocomposite Production

15.8.1 Electrospinning

15.8.2 Wet Spinning

15.8.3 Irradiation Method

15.8.4 Freeze Drying

15.8.5 Solvent Casting/Particulate Leaching

15.8.6 Gas Foaming

15.8.7 Injection/Compression Molding

15.9 Silk Fibroin-Based Biocomposites

15.9.1 Inorganic Nanoparticles and SF

15.9.2 Poly(ethylene glycol) and SF

15.9.3 Poly(pyrrole) and SF

15.9.4 Poly(vinyl alcohol) and SF

15.9.5 Poly(lactic acid) and SF

15.9.6 Poly(ε-caprolactone) and SF

15.9.7 Poly(ε-caprolactone-co-D,L-lactide) and SF

15.9.8 Poly(curethane) and SF

15.9.9 Collagen and SF

15.9.10 Gelatin and SF

15.9.11 Cellulose and SF

15.9.12 Chitin and SF

15.9.13 Chitosan and SF

15.9.14 Hydroxyapatite and SF

15.10 Conclusion

References

16 Design and Manufacturing of Natural Fiber/Synthetic Fiber Reinforced Polymer Hybrid Composites

16.1 Introduction

16.1.1 Prediction of Elastic Properties of Uni-Directional Laminate of Intra-ply Hybrid Composites

16.1.2 Prediction of Elastic Properties of Inter-ply Hybrid Composites

16.1.3 The Hybrid Effect

16.2 Natural Fiber/Synthetic Fiber Hybrid Composites

16.2.1 Natural Fibers, Synthetic Fibers and Polymer Matrices Used in Hybrid Composites and Their Applications

16.2.2 Design

16.2.2.1 Hybrid Composites with Glass Fibers

16.2.2.2 Effects of Hybridization on Moisture Absorption

16.2.2.3 Hybrid Composites with Non-Glass Fibers

16.2.2.4 Biodegradable Matrices

16.2.2.5 Industrial Applications

16.2.3 Manufacturing

16.3 Applications and Future Outlook

16.4 Conclusions

References

17 Natural Fiber Composite Strengthening Solution for Structural Beam Component for Enhanced Flexural Strength, as Alternatives to CFRP and GFRP Strengthening Techniques

17.1 Introduction

17.2 Materials

17.2.1 Materials for FRP System

17.2.2 Pre-treatment of Natural Fibers

17.2.3 Alkali Treatment of Natural Fibers

17.2.4 Bezylation Treatment of Natural Fibers

17.2.5 Thermal Treatment of Natural Fibers

17.3 Mechanical Characterization of Natural and Artificial FRP Composites

17.3.1 Fabrication of FRP Composites

17.3.2 Tensile and Flexural Characterization of FRP Composites

17.4 RC Beam Strengthening Rechnique Using Natural and Artificial FRP Composite Systems

17.5 Experimentation and Analysis of Results

17.5.1 Analysis of Experimental Results

17.6 Conclusions

References

18 High Pressure Resin Transfer Moulding of Epoxy Resins From Renewable Sources

18.1 Introduction

18.2 Experimental

18.2.1 Materials and Methods

18.3 Results and Discussions

18.4 Conclusions

Acknowledgements

References

19 Cork-Based Structural Composites

19.1 Introduction: Cork as a Sustainable Resource

19.2 Cork as a Structural Material

19.2.1 Cork General Properties

19.2.2 Applications

19.2.2.1 Cork Properties

19.2.2.2 Cork Applications

19.2.3 Mechanical Properties

19.2.3.1 Physical Properties

19.2.3.2 Comparison with Foam Cellular Materials

19.2.3.3 Mechanical Properties

19.3 Fibers and Matrices

19.3.1 Fibers

19.3.2 Matrices

19.4 Cork Core Sandwich Concepts

19.5 Damage Tolerant Structures with Cork

19.6 Processing Techniques

19.6.1 Cork Agglomerates

19.6.2 Composite Systems

19.7 Design Philosophy

19.8 Conclusions and Challenges

References

20 The Use of Wheat Straw as an Agricultural Waste in Composites for Semi-Structural Applications

20.1 Introduction

20.2 Application of Wheat Straw in Composites

20.2.1 Composites with Thermosetting Matrices

20.2.2 Composites with Thermoplastic Matrices

20.2.3 Composites with Biodegradable Matrices

20.3 Future Developments

20.4 Conclusions

References

21 Design and Manufacturing of Sustainable Composites

21.1 Introduction to Ecological Composite Design

21.1.1 Historical Background

21.1.2 General Characteristics of Plastics

21.1.3 Use of Ecological Matrices

21.1.3.1 Classical Matrices

21.1.3.2 Matrices from Renewable Resources (Bio-sourced)

21.1.3.3 Biodegradable Matrices from Fossil Resources

21.1.3.4 Biodegradable Matrices from Renewable Resources

21.1.3.5 Oxo-degradable Matrices

21.1.4 Global Production of Plastics

21.1.5 Use of Ecological Fibers

21.1.6 Use of Nanocomposites

21.1.7 Overall Ecological Classification of Composites

21.2 Design Principles for a Sustainable Composite

21.2.1 Composite Applications and Specification of Required Mechanical Goals

21.2.2 Analysis of Ecological and Pure Operational Performance

21.2.2.1 Principles for Sustainable Biomaterials

21.2.2.2 Life Cycle Assessment (LCA)

21.2.3 Predicting the Performance of an Eco-Composite: Relationships Between Microstructural and Mechanical Properties

21.2.3.1 The Rule of Mixtures

21.2.3.2 Shear-lag Model

21.2.3.3 Modified Shear-lag Model

21.2.3.4 Pan Model

21.2.3.5 Christensen-Waals Model

21.2.3.6 Coleman Model

21.3 Summary of Available Composite Manufacturing Processes

21.3.1 Injection Molding

21.3.2 Extrusion

21.3.3 Compression Molding

21.3.4 Hot Pressing

21.3.5 Resin Transfer Molding (RTM)

21.3.6 Industrial Compost Biodegradation Testing

21.4 Techniques for Improving the Thermo-Mechanical Properties of Composites

21.4.1 Useful Optimization Techniques for Eco-Composite Design

21.4.1.1 Maleated Coupling Agents

21.4.1.2 Permanganate Treatment

21.4.1.3 Acetylation of Natural Fibers

21.4.1.4 Alkaline treatment

21.4.1.5 Acrylation and Acrylonitrile Grafting

21.4.1.6 Silane Treatment

21.4.1.7 Peroxide Treatment

21.4.2 The Best Material Design for a Given Application

21.4.3 Certification

Acronym List

References

Index

EULA

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