Abstract

In this work, we conducted an extensive comparative study of the water absorption behavior and retention of mechanical properties of a group of GRP composite laminates manufactured with a range of infusible thermosetting and thermoplastics resins. All laminates were manufactured by Vacuum-Assisted Resin Transfer Moulding (VARTM; the most relevant manufacturing technique in shipbuilding) with a range of state-of-the-art thermosetting resins (Urethane acrylate Crestapol 1210, Epoxy SR1125, Bio-epoxy Supersap CLR, Phenolic Cellobond J2027X) and a novel infusible acrylic thermoplastic resin (Acrylic Elium 150). The reinforcement of choice for each laminate was a unidirectional glass fabric of 996 gsm. Sample preparation for water immersion studies was according to ASTM D5229. This study was part of a comprehensive down-selection of commercially available resins in terms of their suitability for shipbuilding applications, as part of the EU H2020 project FIBRESHIP2 .  A selection of relevant properties of the laminates with different resin systems is presented in this paper including fibre volume fraction, apparent interlaminar shear strength (dry and wet condition), flexural strength (dry and wet condition) and flexural modulus (dry and wet condition).

Abstract

This work investigated the feasibility of the use of a novel infusible thermoplastic resin (Elium 150 from Arkema) for composite laminate manufacture by resin infusion methods and possible application in the shipbuilding sector. We compared the properties of Elium glass-fibre laminates with those of laminates infused with state-of-the-art thermosetting epoxy and urethane acrylate resins. The Elium laminates matched the mechanical performance (flexure and interlaminar shear strength) of the epoxy and surpassed that of the urethane acrylate counterpart. However, the mechanical performance of the Elium laminates after immersion in water at 35 oC for 28 days deteriorated compared to urethane acrylate, but was comparable in flexural properties to that of the epoxy. The combination of superior mechanical performance coupled with acceptable environmental resistance and comparable composite laminate manufacturing conditions makes the infusible thermoplastic a possible future candidate matrix over commercial thermosetting resin options.

Abstract

Fibre-reinforced polymers (FRP) are extensively used in the marine industry for the manufacture of lightweight hull structures for vessels up to 50m in length, and for secondary structures and components in larger vessels. The main benefits resulting in the application of FRP in shipbuilding include: significant weight reduction resulting in substantial fuel saving, increase in cargo capacity and subsequent reduction of greenhouse gas emissions, improved life cycle performance and reduced maintenance costs due to corrosion resistance. As the use of thermoset polymers in shipbuilding increases, so too does the interest in finding suitable alternatives to the use of petroleum-based raw materials. Much work has been published on bio-based epoxy resin systems from natural raw materials, such as vegetable oils, however, the mechanical performance of the bio-based resin systems in comparison to equivalent petroleum-based systems is not widely documented. This research focusses on the comparison of petroleum-based and bio-based two-part commercial epoxy resin systems to manufacture glass fibre reinforced polymers (GFRP) for marine applications. Laminates were manufactured using the Vacuum Assisted Resin Transfer Moulding (VARTM) manufacturing process. Specimens were mechanically characterised in order to evaluate fibre volume fraction, density, apparent inter-laminar shear strength, flexural modulus and strength. The effect of water ingress on the mechanical properties of laminates was also studied by soaking samples in water at 35°C for 28 days. Specimen quality and fracture surfaces were assessed using optical and scanning electron microscopy. Initial results have shown that the average apparent inter-laminar shear strength of the petroleum-based samples was almost identical to the bio-based samples (within 1%), while the flexural strength and modulus of the petroleum-based samples was only 6% and 7% higher than the bio-based samples. Despite the comparatively good mechanical performance of the bio-based laminate, the high viscosity of the resin resulted in higher infusion temperatures and longer infusion times than for the petroleum-based epoxy.