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Characterization of glass-epoxy composites using red brick dust particles
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ScienceDirect Materials Today: Proceedings 18 (2019) 3775–3779
www.materialstoday.com/proceedings
ICMPC-2019
Characterization of glass-epoxy composites using red brick dust particles Pravat Ranjan Pati* Department of Mechanical EngineeringFaculty of Science & Technology, ICFAI Foundation for Higher Education, Hyderabad
Abstract Now-a-days, the solid wastes are used in many areas of manufacturing. But the utilization of these wastes in polymer composites has rarely been seen. Therefore, exploring new avenues for its application would be an exciting task as far as the materials recycle aspect is concerned. This article presents the fabrication and investigation of physical and mechanical properties of glass fiber reinforced epoxy composites with red brick dust (RBD). RBD is the waste or leftover powder, or the powder formed from deformed bricks in the process of their manufacturing. Bricks can be deformed while handling and the deformed bricks cannot be used for construction purposes; hence, they are dumped as waste. Hand lay-up technique is used for composite fabrication. RBD is varied from 0 to 30% by weight and physical and mechanical tests are performed on the composite samples. X-ray diffractography (XRD) is carried out in order to identify the phases present in raw RBD. This work shows that density, void content, hardness and impact strength of the composites increases with the increase in red brick dust content while the decrease in tensile and flexural properties are observed. © 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the 9th International Conference of Materials Processing and Characterization, ICMPC-2019 Keywords: Characterization; RBD; Glass fiber; Waste; XRD
1. Introduction Fiber reinforced polymer composites are extensively used as wind turbine blade material due to their valuable characteristics. The various valuable characteristics of composites include higher strength and stiffness at low density with excellent wear resistance. Due to higher mechanical properties, glass fibers are used as reinforcement in polymer composites. Many researchers have investigated and reported the influence of glass fibers on mechanical
* Corresponding author. Tel.: +91 9437218710 E-mail address: [email protected] 2214-7853 © 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the 9th International Conference of Materials Processing and Characterization, ICMPC-2019
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P. R. Pati et al. / Materials Today: Proceedings 18 (2019) 3775–3779
characteristics of polymer composites [1-5]. Fu and Lauke [6] have analyzed the tensile properties of FRP composites and acrylonitrile-butadiene-styrene (ABS) and found that the strength of the composite reduces with the addition of these particles. Mishra et al. [7] investigated the mechanical properties of metal matrix composites. They found that the properties such as hardness, tensile and impact strength are improving except flexural strength. Asi [8] developed FRP composites filled with aluminium oxide and the results indicate that the bearing strength of the composites increases with increase in Al2O3 particles. Su et al. [9] examined the tensile and adhesion strength of the carbon fabric composites filled with nano-particulates and observed that both the strengths are increasing significantly. The physical and mechanical properties of polyester hybrid composites have been tested by Patnaik et al. [10]. They concluded that density, hardness and tensile strength decreases with the incorporation of these filler particles while a steady rise in flexural strength is observed and further, decreasing beyond a filler content of 10 wt%. Kim et al. [11] described the hardness and tensile properties of short glass fiber reinforced PA 12 composite and reported that the hardness and strength of the composite are increased as a function of the glass fiber contents. Siddhartha et al. [12] developed titania reinforced filled functionally graded composites by using vertical centrifugal casting technique and studied the mechanical properties of these composites. Patnaik et al. [13] also studied the hardness, density, and strength properties of glass fiber-reinforced polyester composites. The tensile strength of red mud filled polyester composites is examined by Satapathy and Patnaik [14] and they found that the strength of the composites decrease with rise in filler content. Ahmed et al. [15] described all the mechanical testing of epoxy composites reinforced with woven jute fabric. However, the utilization of glass fiber-reinforced composites using solid wastes is rarely found in the literature. Thus, the current effort is to explore the probable use of waste material (RBD) as filler in polymer matrix composites. 2. Experimental details 2.1. Process of composite fabrication A sequence of composites are fabricated keeping glass fiber and epoxy resin constant and varying red brick dust in a stable manner as shown in Table 1 through efficient increase in red brick dust (0, 10, 20 and 30 wt%). The epoxy resin and corresponding hardener are slowly mixed by using hand. During mixing, RBD is poured into the resin in different weight proportions. Then, the mixed dough is stirring for some time. A silicone-releasing agent is sprayed over glass molds before the mixture poured into it to easy removal of the fabricated composite from the mold after curing. The setup is then kept at room temperature for 24 hours for initial curing to obtain the required composite. The chemical compositions of RBD are given in Table 2. Table 1. Designation and composition of the composites Designation
Composition
C1
Epoxy + 15 wt% SGF + 0 wt% RBD
C2
Epoxy + 15 wt% SGF + 10 wt% RBD
C3
Epoxy + 15 wt% SGF + 20 wt% RBD
C4
Epoxy + 15 wt% SGF + 30 wt% RBD
2.2. Mechanical Characterization The experimental density of the composites is computed by simple water immersion technique whereas void content is calculated by normalizing theoretical density with actual density. The hardness of the composites is obtained using Vickers micro-hardness tester. The tensile test is conducted on flat composite specimens on universal testing machine (UTM). The flexural test is also performed using the same machine i.e. UTM. The impact tests are done using an impact tester on composite specimens.
P.R. Pati et al. / Materials Today: Proceedings 18 (2019) 3775–3779
3777
Table 2. Chemical composition of RBD Constituent
Content (wt%)
Si02
52
Al203
41
CaO
4.32
Fe203
0.7
MgO
0.12
K20
0.53
Ti02
0.65
Na20
0.05
LOI
2.01
3. Results and discussion 3.1. X-ray Diffraction XRD analysis is conducted on raw red brick dust with an X-ray diffractometer with Cu Kα radiation, shown in Fig. 1. From the diffractogram, it is seen that the major oxide phases present are silica (SiO2), alumina (Al2O3) and lime (CaO).
Fig. 1 X ray diffractogram of raw RBD
3.2. Physical and Mechanical properties The results of density and void content of the fabricated composites are presented in Table 3. It is observed that, the density and void content of the composites increased with corresponding rise in RBD content. The value of measured density for composite is obtained in the range of 1.181 g/cm3 to 1.437 g/cm3 and void content in between 1.254% to 3.686%.
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P. R. Pati et al. / Materials Today: Proceedings 18 (2019) 3775–3779 Table 3. Density and void content of the fabricated composites RBD content
Theoretical Density (g/cm3)
Measured Density (g/cm3)
Void Content (%)
0
1.196
1.181
1.254
10
1.294
1.273
1.622
20
1.387
1.355
2.307
30
1.492
1.437
3.686
(wt%)
Fig. 2 illustrates the variation in hardness of the considered composites. The hardness of the composites is observed to be in the range of 20.23-41.68 Hv, and further in all cases, hardness increased with increase in RBD content. The composite without red brick dust exhibits the lowest hardness value of 20.23 Hv and a maximum of 41.68 Hv for the 30 wt% RBD filled composites. Fig. 3 shows the variation in tensile strength and tensile modulus of the composites. The tensile strength is found to be varies from 209.51-146.86 MPa. So, it is in decreasing order as the RBD content increase from 0 to 30 wt%. This nature of decreasing is due to the present of pores in the composite. The result also shows that the values of tensile modulus of the composite are found to be decreasing in the range of 4.93-3.21 GPa as the RBD content in them increases. The variation in flexural strength and flexural modulus of the composites are shown in Fig. 4. It is seen that both the strength and modulus in decreasing manner as the RBD content varying from 0 to 30 wt%. The composite without red brick dust exhibits a maximum strength and modulus of 192.24 MPa and 3.84 GPa respectively and the lowest value of 137.28 MPa and 2.13 GPa for the 30 wt% RBD filled composites respectively. This reduction may be attributed to poor interfacial bonding in the composites.
250
50
10
Strength Modulus 200
8
150
6
100
4
50
2
30
Tensile modulus (GPa)
Tensile strength (MPa)
Micro-hardness (Hv)
40
20
10
0 0
10
20
30
Filler content (wt%)
Fig. 2 Variation in hardness of the composites
0 0
10
20
30
Filler content (wt%)
Fig. 3 Variation in tensile strength and tensile modulus of the composites
Fig. 5 presents the variation in impact strength of the composites. The strength of a material is increasing as the RBD content in the composite increase from 0 to 30 wt%. It is found to be 25.5 kJ/m2 without red brick dust and 33.6, 38.3, 44.2 kJ/m2 for 10, 20 and 30 wt% respectively.
P.R. Pati et al. / Materials Today: Proceedings 18 (2019) 3775–3779
250
3779
50
10
Strength Modulus 200
8
6
100
4
50
2
2
Impact strength (kJ/m )
150
Flexural modulus (GPa)
Flexural strength (MPa)
40
30
20
0
0 0
10
20
30
Filler content (wt%)
Fig. 4 Variation in flexural strength and flexural modulus of the composites
10 0
10
20
30
Filler content (wt%) Fig. 5 Variation in impact strength of the composites
4. Conclusions The influence of various percentages of red brick dust loading in glass fiber reinforced epoxy composites on physical and mechanical properties are studied. It is found that the density, void content, hardness, and impact strength of the composites increased with increasing RBD content, whereas both the strength and modulus are decreasing. Increased filler content has a positive effect on the mechanical properties of theses composites. This study contributes a novel opportunity for utilization of material such as RBD as reinforcing potential in polymer composites. References [1] S. Biswas, B. Deo, A. Patnaik, A. Satapathy, Polym. Compos. 32 (2011) 665-674. [2] N.A. Rahman, A. Hassan, R. Yahya, R.A. Lafia-Araga, Fibers Polym. 14 (2013) 1877-1885. [3] S. Biswas, A. Satapathy, Materials and Design 31 (2010) 1752-1767. [4] S. Biswas, A. Satapathy, Tribol. Trans. 53 (2010) 520-532. [5] A.K. Rout, A. Satapathy, Mater. Des. 41 (2012) 131-141. [6] S. Fu, B. Lauke, Composites Part A 29 (1998) 575-583. [7] S.K. Mishra, S. Biswas, A. Satapathy, Materials and Design 55 (2014) 958-965. [8] O. Asi, Composite Structures 92 (2010) 354-363. [9] F. Su, Z. Zhang , W. Liu, Wear 260 (2006) 861-868. [10] A. Patnaik, A. Satapathy, S.S. Mahapatra , R.R. Dash, Materials and Design 30 (2009) 57-67. [11] S.S. Kim, M.W. Shin, H. Jang, Wear 274-275 (2012) 34-42. [12] Siddhartha, A. Patnaik, A.D. Bhatt, Materials and Design 32 (2011) 615-627. [13] A. Patnaik, A. Satapathy, S.S. Mahapatra, R.R. Dash, Journal of Reinforced Plastics and Composites 27 (2008) 1039-1058. [14] A. Satapathy, A. Patnaik, Journal of Reinforced Plastics and Composites 29 (2010) 2883- 2897. [15] K.S. Ahmed, V. Mallinatha, S.J. Amith, Journal of Reinforced Plastics and Composites 30 (2011) 1315-1326.
ScienceDirect Materials Today: Proceedings 18 (2019) 3775–3779
www.materialstoday.com/proceedings
ICMPC-2019
Characterization of glass-epoxy composites using red brick dust particles Pravat Ranjan Pati* Department of Mechanical EngineeringFaculty of Science & Technology, ICFAI Foundation for Higher Education, Hyderabad
Abstract Now-a-days, the solid wastes are used in many areas of manufacturing. But the utilization of these wastes in polymer composites has rarely been seen. Therefore, exploring new avenues for its application would be an exciting task as far as the materials recycle aspect is concerned. This article presents the fabrication and investigation of physical and mechanical properties of glass fiber reinforced epoxy composites with red brick dust (RBD). RBD is the waste or leftover powder, or the powder formed from deformed bricks in the process of their manufacturing. Bricks can be deformed while handling and the deformed bricks cannot be used for construction purposes; hence, they are dumped as waste. Hand lay-up technique is used for composite fabrication. RBD is varied from 0 to 30% by weight and physical and mechanical tests are performed on the composite samples. X-ray diffractography (XRD) is carried out in order to identify the phases present in raw RBD. This work shows that density, void content, hardness and impact strength of the composites increases with the increase in red brick dust content while the decrease in tensile and flexural properties are observed. © 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the 9th International Conference of Materials Processing and Characterization, ICMPC-2019 Keywords: Characterization; RBD; Glass fiber; Waste; XRD
1. Introduction Fiber reinforced polymer composites are extensively used as wind turbine blade material due to their valuable characteristics. The various valuable characteristics of composites include higher strength and stiffness at low density with excellent wear resistance. Due to higher mechanical properties, glass fibers are used as reinforcement in polymer composites. Many researchers have investigated and reported the influence of glass fibers on mechanical
* Corresponding author. Tel.: +91 9437218710 E-mail address: [email protected] 2214-7853 © 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the 9th International Conference of Materials Processing and Characterization, ICMPC-2019
3776
P. R. Pati et al. / Materials Today: Proceedings 18 (2019) 3775–3779
characteristics of polymer composites [1-5]. Fu and Lauke [6] have analyzed the tensile properties of FRP composites and acrylonitrile-butadiene-styrene (ABS) and found that the strength of the composite reduces with the addition of these particles. Mishra et al. [7] investigated the mechanical properties of metal matrix composites. They found that the properties such as hardness, tensile and impact strength are improving except flexural strength. Asi [8] developed FRP composites filled with aluminium oxide and the results indicate that the bearing strength of the composites increases with increase in Al2O3 particles. Su et al. [9] examined the tensile and adhesion strength of the carbon fabric composites filled with nano-particulates and observed that both the strengths are increasing significantly. The physical and mechanical properties of polyester hybrid composites have been tested by Patnaik et al. [10]. They concluded that density, hardness and tensile strength decreases with the incorporation of these filler particles while a steady rise in flexural strength is observed and further, decreasing beyond a filler content of 10 wt%. Kim et al. [11] described the hardness and tensile properties of short glass fiber reinforced PA 12 composite and reported that the hardness and strength of the composite are increased as a function of the glass fiber contents. Siddhartha et al. [12] developed titania reinforced filled functionally graded composites by using vertical centrifugal casting technique and studied the mechanical properties of these composites. Patnaik et al. [13] also studied the hardness, density, and strength properties of glass fiber-reinforced polyester composites. The tensile strength of red mud filled polyester composites is examined by Satapathy and Patnaik [14] and they found that the strength of the composites decrease with rise in filler content. Ahmed et al. [15] described all the mechanical testing of epoxy composites reinforced with woven jute fabric. However, the utilization of glass fiber-reinforced composites using solid wastes is rarely found in the literature. Thus, the current effort is to explore the probable use of waste material (RBD) as filler in polymer matrix composites. 2. Experimental details 2.1. Process of composite fabrication A sequence of composites are fabricated keeping glass fiber and epoxy resin constant and varying red brick dust in a stable manner as shown in Table 1 through efficient increase in red brick dust (0, 10, 20 and 30 wt%). The epoxy resin and corresponding hardener are slowly mixed by using hand. During mixing, RBD is poured into the resin in different weight proportions. Then, the mixed dough is stirring for some time. A silicone-releasing agent is sprayed over glass molds before the mixture poured into it to easy removal of the fabricated composite from the mold after curing. The setup is then kept at room temperature for 24 hours for initial curing to obtain the required composite. The chemical compositions of RBD are given in Table 2. Table 1. Designation and composition of the composites Designation
Composition
C1
Epoxy + 15 wt% SGF + 0 wt% RBD
C2
Epoxy + 15 wt% SGF + 10 wt% RBD
C3
Epoxy + 15 wt% SGF + 20 wt% RBD
C4
Epoxy + 15 wt% SGF + 30 wt% RBD
2.2. Mechanical Characterization The experimental density of the composites is computed by simple water immersion technique whereas void content is calculated by normalizing theoretical density with actual density. The hardness of the composites is obtained using Vickers micro-hardness tester. The tensile test is conducted on flat composite specimens on universal testing machine (UTM). The flexural test is also performed using the same machine i.e. UTM. The impact tests are done using an impact tester on composite specimens.
P.R. Pati et al. / Materials Today: Proceedings 18 (2019) 3775–3779
3777
Table 2. Chemical composition of RBD Constituent
Content (wt%)
Si02
52
Al203
41
CaO
4.32
Fe203
0.7
MgO
0.12
K20
0.53
Ti02
0.65
Na20
0.05
LOI
2.01
3. Results and discussion 3.1. X-ray Diffraction XRD analysis is conducted on raw red brick dust with an X-ray diffractometer with Cu Kα radiation, shown in Fig. 1. From the diffractogram, it is seen that the major oxide phases present are silica (SiO2), alumina (Al2O3) and lime (CaO).
Fig. 1 X ray diffractogram of raw RBD
3.2. Physical and Mechanical properties The results of density and void content of the fabricated composites are presented in Table 3. It is observed that, the density and void content of the composites increased with corresponding rise in RBD content. The value of measured density for composite is obtained in the range of 1.181 g/cm3 to 1.437 g/cm3 and void content in between 1.254% to 3.686%.
3778
P. R. Pati et al. / Materials Today: Proceedings 18 (2019) 3775–3779 Table 3. Density and void content of the fabricated composites RBD content
Theoretical Density (g/cm3)
Measured Density (g/cm3)
Void Content (%)
0
1.196
1.181
1.254
10
1.294
1.273
1.622
20
1.387
1.355
2.307
30
1.492
1.437
3.686
(wt%)
Fig. 2 illustrates the variation in hardness of the considered composites. The hardness of the composites is observed to be in the range of 20.23-41.68 Hv, and further in all cases, hardness increased with increase in RBD content. The composite without red brick dust exhibits the lowest hardness value of 20.23 Hv and a maximum of 41.68 Hv for the 30 wt% RBD filled composites. Fig. 3 shows the variation in tensile strength and tensile modulus of the composites. The tensile strength is found to be varies from 209.51-146.86 MPa. So, it is in decreasing order as the RBD content increase from 0 to 30 wt%. This nature of decreasing is due to the present of pores in the composite. The result also shows that the values of tensile modulus of the composite are found to be decreasing in the range of 4.93-3.21 GPa as the RBD content in them increases. The variation in flexural strength and flexural modulus of the composites are shown in Fig. 4. It is seen that both the strength and modulus in decreasing manner as the RBD content varying from 0 to 30 wt%. The composite without red brick dust exhibits a maximum strength and modulus of 192.24 MPa and 3.84 GPa respectively and the lowest value of 137.28 MPa and 2.13 GPa for the 30 wt% RBD filled composites respectively. This reduction may be attributed to poor interfacial bonding in the composites.
250
50
10
Strength Modulus 200
8
150
6
100
4
50
2
30
Tensile modulus (GPa)
Tensile strength (MPa)
Micro-hardness (Hv)
40
20
10
0 0
10
20
30
Filler content (wt%)
Fig. 2 Variation in hardness of the composites
0 0
10
20
30
Filler content (wt%)
Fig. 3 Variation in tensile strength and tensile modulus of the composites
Fig. 5 presents the variation in impact strength of the composites. The strength of a material is increasing as the RBD content in the composite increase from 0 to 30 wt%. It is found to be 25.5 kJ/m2 without red brick dust and 33.6, 38.3, 44.2 kJ/m2 for 10, 20 and 30 wt% respectively.
P.R. Pati et al. / Materials Today: Proceedings 18 (2019) 3775–3779
250
3779
50
10
Strength Modulus 200
8
6
100
4
50
2
2
Impact strength (kJ/m )
150
Flexural modulus (GPa)
Flexural strength (MPa)
40
30
20
0
0 0
10
20
30
Filler content (wt%)
Fig. 4 Variation in flexural strength and flexural modulus of the composites
10 0
10
20
30
Filler content (wt%) Fig. 5 Variation in impact strength of the composites
4. Conclusions The influence of various percentages of red brick dust loading in glass fiber reinforced epoxy composites on physical and mechanical properties are studied. It is found that the density, void content, hardness, and impact strength of the composites increased with increasing RBD content, whereas both the strength and modulus are decreasing. Increased filler content has a positive effect on the mechanical properties of theses composites. This study contributes a novel opportunity for utilization of material such as RBD as reinforcing potential in polymer composites. References [1] S. Biswas, B. Deo, A. Patnaik, A. Satapathy, Polym. Compos. 32 (2011) 665-674. [2] N.A. Rahman, A. Hassan, R. Yahya, R.A. Lafia-Araga, Fibers Polym. 14 (2013) 1877-1885. [3] S. Biswas, A. Satapathy, Materials and Design 31 (2010) 1752-1767. [4] S. Biswas, A. Satapathy, Tribol. Trans. 53 (2010) 520-532. [5] A.K. Rout, A. Satapathy, Mater. Des. 41 (2012) 131-141. [6] S. Fu, B. Lauke, Composites Part A 29 (1998) 575-583. [7] S.K. Mishra, S. Biswas, A. Satapathy, Materials and Design 55 (2014) 958-965. [8] O. Asi, Composite Structures 92 (2010) 354-363. [9] F. Su, Z. Zhang , W. Liu, Wear 260 (2006) 861-868. [10] A. Patnaik, A. Satapathy, S.S. Mahapatra , R.R. Dash, Materials and Design 30 (2009) 57-67. [11] S.S. Kim, M.W. Shin, H. Jang, Wear 274-275 (2012) 34-42. [12] Siddhartha, A. Patnaik, A.D. Bhatt, Materials and Design 32 (2011) 615-627. [13] A. Patnaik, A. Satapathy, S.S. Mahapatra, R.R. Dash, Journal of Reinforced Plastics and Composites 27 (2008) 1039-1058. [14] A. Satapathy, A. Patnaik, Journal of Reinforced Plastics and Composites 29 (2010) 2883- 2897. [15] K.S. Ahmed, V. Mallinatha, S.J. Amith, Journal of Reinforced Plastics and Composites 30 (2011) 1315-1326.