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8/3/2019 EBB 427 (6) Pultrusion Hazizan
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EBB 427 Application and Technology ofEngineering Polymers (Second Half)
Dr. Hazizan Md Akil
School of Materials and Mineral Resources EngineeringEngineering Campus, USM.
PULTRUSION PROCESSINGTECHNOLOGY
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Pultrusion Technology
Introduction
Pultrusion is a continuous, automated closed-mouldingprocess that is cost effective for high volume productionof constant cross section parts.
Due to uniformity of cross-section, resin dispersion, fiber
distribution & alignment, excellent composite structuralmaterials can be fabricated by Pultrusion
The basic process usually involves pulling of continuousfibers through a bath of resin, blended with a catalyst and
then into pre-forming fixtures where the section ispartially pre-shaped & excess resin is removed
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Pultrusion Technology
Introduction
It is then passed through a heated die, which determinesthe sectional geometry and finish of the final product.
The profiles produced with this process can compete withtraditional metal profiles made of steel & aluminium for
strength & weight. The Pultrusion process has developed slowly compared
to other composite fabrication processes
The initial pultrusion patent in the United States was
issued in 1951
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Pultrusion Technology
Introduction
In the early 1950s pultrusion machines for the productionof simple solid rod stock were in operation at severalplants
Most of these machines were the intermittent pull type
In the mid-1950s, continuous pull machines wereavailable
The late 1950s were producing pultruded structuralshapes and by 1970, there has been a dramatic increase
in market acceptance, technology development, andPultrusion industry sophistication.
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Pultrusion Technology
Introduction
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Pultrusion Technology
The Process
The process begins when reinforcing fibers are pulledfrom a series of creels.
The fibers proceed through a bath, where they areimpregnated with formulated resin
The resin-impregnated fibers are preformed to the shapeof the profile to be produced.
This composite material is then passed through a heatedsteel die that has been machined precisely to the final
shape of the part to be manufactured
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Pultrusion Technology
The Process
Heat initiates an exothermic reaction thus curing thethermosetting resin matrix
The profile is continuously pulled and exits the mould asa hot, constant cross sectional member
The profile cools in ambient or forced air, or assisted bywater.
The product emerges from the puller mechanism and iscut to the desired length by an automatic, flying cutoff
saw.
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Pultrusion Technology
The Process
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Pultrusion Technology
Advantages
Pultrusion is the most cost-effective method of producingfiber-reinforced composite structural profiles
The process is capable of producing high performancecomposite of various continuous profiles, typically
products such as light-weight corrosion free structures,electrical non-conductive systems, off-shore platformsand many other innovative new products from Researchand Development to mass production and
commercialization There are numerous advantages of pultruded Fiber
Reinforced Polymer (FRP) profiles of which can besummarized as shown in Table 1.
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Pultrusion TechnologyFeatures Description Benefits Applications
Strong
Unit strength in tension &compression is approx. 20 x
that of steel when theseproperties are combined on
the basis of unit density
Optional strength as desired.Exceptionally high impactstrength reduces damage
potential
Structural process equipmentsupport. Tank supports.
Cooling tower ancillaries.Flooring supports. Trusses &
joints.
Light WeightDensity of pultruded components
is about 20% of steel and60% of aluminium
Higher performance at less weight.Lower shipping, handling &
installation costs. Lessoperational energy demand.
Automotive leaf springs & bumpers.Prefabricated walkways &
platforms. Bus components.
CorrosionResistant
Unaffected by exposure to a greatvariety of corrosive
environment & chemicals.
Minimum maintenance costs. Longterm safety. Longer life.
Chemical plant hand railings,gratings, walkways & bridges.
Cable trays. Pipe supports.
ElectricalInsulation
Provides strength & rigidity withdielectric properties.
Lesser no. of components. Non-
magnetic & safe. Predictableinsulation values for wide
range of frequencies.
Ladders, Cable trays. Switch gearcomponents. Mounting bracesand backboards.
ThermalInsulation
Pultruded components have a lowthermal conductivity, 1/250
of aluminium & 1/60 of steel.
Reduces installation thickness.Eliminates condensation
problems. Reduces energyoperation requirements.
Bulk head frames. Walk inrefrigerator door jams. Windowframes. Insulated roll up panel
doors.
ConsolidationMany individual components can
be combined into a large
profile.
Reduced assembly cost. Reducedinventory. Fewer parts
improve reliability.
Window latch supports. Roll up door
DimensionalStability
Pultruded components are highlyresistant to warping
stretch/swelling over a widerange of temperature &
stresses.
No permanent deformation underhigh stress. Close tolerances.
Spring bumpers. Crossing gate arms.Scrubber components.
Safety
The pultruded components arevery strong & safe to work
with. They are microbes andinsect proof.
Many gratings suffer from theproblem of microbes etc. dueto wet or unhygienic working
conditions.
This property makes them idealchoice for pharmaceutical &
food industries.
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Applications of Pultrusion Technology
Application Areas of Pultrusion
Electrical
32%
Building &
Construction
17%
Transport
10%
Industrial
17%
Recreation
7%
Other
17%
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Pultrusion Technology
Fig. 3: Stork Bridge, Switzerland (Glass Fiber Reinforced Polymer) built in 1996
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Pultrusion Technology
Kempt Bridge Switzerland (FRP Composite Pedestrian Bridge built in year 2001)
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Pultrusion Technology
Kolding Bridge, Denmark (GRP composite bridge) was opened on 18th July, 1997)
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Pultrusion Technology
Grating products for sewer or drainage system-reducing the maintenance cost
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Pultrusion Technology
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