BURST FAILURE OF BASALT FIBER REINFORCED FILAMENT WOUND PIPE M. Turan DEMİRCİ 1, Necmettin TARAKÇIOĞLU 2, Ahmet AVCI 3, Rıfat YAKUT 4 1 Selçuk Üniversitesi Teknik Eğitim Fakültesi, Makine Eğitimi Bölümü, 42003, Konya, E-posta: turandemirci@selcuk.edu.tr 2 Selçuk Üniversitesi Teknik Eğitim Fakültesi, Makine Eğitimi Bölümü, 42003, Konya, E-posta: ntarakcioglu@selcuk.edu.tr 3 Selçuk Üniversitesi Mühendislik-Mimarlık Fakültesi, Makine Mühendisliği Bölümü, 42003, Konya, E-posta: aavci@selcuk.edu.tr Hema Endüstri A.S. Organize Sanayi bölgesi, 59501, Çerkezköy, Tekirdağ, Türkiye E-posta: rifatyakut@hattat.com.tr ABSTRACT The polymer matrix composites are used in many applications due to provide many advantages; like low cost, weight, high strength and corrosive resistance. The filament winding process is one of the production methods of polymer matrix. These types of materials are commonly used as high pressure containers, gas and liquid transfer liquid, mobile bridging components and military applications. Glass fiber reinforced (GFR) polymer pipes are widely used but strength of GFR pipe is lower than Carbon fiber and Basalt fiber reinforcement. Carbon fiber reinforcement (CFR) has the highest mechanical properties but its cost so high. However, the usage of basalt fiber reinforcement (BFR) ensures higher strength than E-Glass Fiber reinforcement and has lower cost than CFR. In present study, ± 55 BFR 12 layers filament wound pipes under internal pressure were investigated experimentally. BFR pipes were made of Basalt fiber/epoxy and open ended condition. By this experimental method, mechanical behavior of ± 55 BFR pipes was determined. To find possion ratio and young modules strain gage were used. End of experiment, the mechanical comparisons of GFR which tested before in Samanci s study were made for same thickness. BFR pipe shows high mechanical properties and to determine burst effects of BFR pipe microstructure investigation carried out. Key Words: Basalt fiber, filament wound, burst failure 1. INTRODUCTION Basalt fiber reinforcement to polymers is increasingly used in the industry and plays a significant role in engineering polymer materials for many applications. These reinforcement materials are generally used in high pressure containers which gas and liquid gas such as natural gas, hydrogen gas are deposited, gas transfer pipes, mobile bridging components, trusses, bridge piers and other applications etc. These reinforced composites have high strength-to-weight ratio and fine corrosion resistance. Composite applications for gas cylinders are widely available on industry and they have many advantages and disadvantages. The weight of metal cylinders is an important disadvantage. The weight of a cylinder is reduced by using the reinforced polymers instead of metals. These cylinders maintain their durability due to their high strength and light weight epoxy matrix impregnated carbon fibers used. However, high price and current shortage of carbon fiber cause to high manufacturing cost. Basalt fiber has higher mechanical properties than E- glass fiber and cheaper than carbon fiber. These advantages could be a good alternative for gas storage vessels and pipes. Basalt fiber is readily available natural materials and produced from volcanic rocks that are found worldwide. Basalt fiber is environmental and non hazardous materials. Filament winding method is automated process which allows a thermoset resin-impregnated glass, carbon and basalt reinforcement to be wrapped around a suitable mandrel. The filament winding machine wraps the mandrel Proceedings of IMSP'2012 287
with resin-impregnated strands with the required amount and orientation to build the designed reinforced structure. After that winding process, the component is cured under high pressure and temperature. Considerable advantages include precise fiber orientations. Mechanical properties of the filament wound parts do not just depend from composition of component material. In addition, process parameters like winding angle, fiber tension, resin type and curing cycle effects the mechanical properties of filament wound parts. [Pavloski et al, 2007), (Zhu Lvtao et al., 2010), (Kaynak and Mat, 2001), (Gemi et al., 2009). Tarakcioglu et al. theoretically and experimentally investigated the effect of surface cracks on strength of glass/epoxy filament wound pipes and fatigue failure behavior of glass/epoxy (±55) filament wound pipes under internal pressure( Tarakcioglu et al., 2005). Avci et al. investigated the fatigue behavior of surface cracked filament wound GRP pipes in corrosive environment (Avci et al., 2007). Martens and Ellyin studied on the filament wound GFR pipes at different winding angles. They applied to tensile test on pipe specimens and concluded that as winding angle increased, tension strength increased(mertiny and Ellyin, 2000). Samanci et al. concentrated on open ended fatigue of ± 75 o filament wound pipes which can be deformed freely in the axial direction. Surface cracks were machined in the axial direction of the pipes which have depth to thickness ratios and these Glass fiber reinforced pipe (GFR) samples were carried out fatigue tests and they determined the fatigue life of GFR pipes (Samanci et al. 2008). Gemi et al. studied on GFR filament winding pipe and examined fatigue life of these pipes like Samanci s study. Martens and Ellyin presented the investigation of the biaxial monotonic behavior of a filament wound multi directional glass fiber/epoxy pipe (Gemi et al., 2009). In this study, we aimed to investigate experimentally burst failure of basalt/epoxy ± 55 o filament wound pipes under internal pressure. BFR pipes are made of BFR/epoxy and open ended condition. Whitening and final bust failure levels of BFR pipes have been observed. 2. MATERIAL AND METHOD Basalt fiber with 400 Tex (BFR) and 11 μ m diameter is used as reinforcement and Ciba Geigy Bisphenol-A Epoxy CY225 resin system is used as matrix. Mechanical properties of composites (matrix and reinforcement are given in Table 1. The filament wound pipes are produced at the filament winding facilities of commercial filament winding company. The wet winding method used for the production of the composite pipes with ± 55 o lay-up. The geometry of composite specimen is shown in Fig. 1. 12 layer of reinforcement thickness 2.25 mm [8-10]. Produced BFR composite pipe specimens are exhibited in Fig. 2. Figure 1. Geometry of specimen (Demirci et al. 2011), (Samanci et al., 2004).
Figure 2. BFR and GFR filament wound pipes Open ended internal pressure test apparatus are given in Fig. 3. According to ASTM D2992 standard. To determine other mechanical properties, axial and tangential LY13 type strain gages were placed on midpoint of basalt fiber which is given Fig.4. Figure 3. Open ended internal pressure test apparatus (Demirci et al. 2011), (Samanci et al. 2004). Figure 4. Burn-off test of BFR composite pipes.
3. RESULTS AND DISCUSSION Burst failure and damage formation of filament wound BFR pipes were investigated with internal pressure experiments. Internal pressure stress-strain values ( σ ε) of BFR pipes are give in fig.5. Figure 5. Internal pressure stress-strain values of ± 55 o open ended BFR pipes. End of internal pressure tests by using strain gages, mechanical properties of BFR pipes were found. These properties are presented in Table 1. Table 1. Mechanical properties of BFR composite pipe o The first failure sign was the formation of whiting line on ± 55 filament wound BFR pipes. This failure occurred and progressed thin white lines parallel to fiber direction due to the departure of fiber from matrix all along pipe. As increasing internal pressure, the failure mechanism occurred as layer separation. The increasing pressure increased swelling of pipe at center zone and so diameter of pipe especially at center zone extended. In addition the pipe length got short by increasing pressure. The whiting failure firstly were seen about 375-390 MPa stress values. Then, the increasing pressure caused to consecutively separation of layers. End of step, basalt fibers were exposed the last failure by tearing as fiber breakage at 615 MPa. These failure mechanisms are indicated on BFR composite pipe in Fig. 6, 7, 8. When Samanci s study were investigated, whiting failure and burst failure were observed about 100 MPa and 405 MPa stress values respectively and elasticity modules were found to be about 23,17 GPa. Our experimental results show that the whiting and burst failure of BFR pipes has higher than GFR pipes as well as elasticity of BFR pipes. Burst failure of BFR pipes are presented in fig. 6.
Figure 6. Burst o ± 55 filament wound BFR pipes. Fig. 7. Whitening and the departure of fiber matrix of BFR composite pipe.
4. CONCLUSION Figure 8. Fiber breakage and final failure of BFR composite pipe. As results of experiments of open ended internal pressure, the mechanical properties of BFR pipes were determined and compared with GFR pipes. Obtained inferences from experiments can be itemized below. The increasing internal pressure increase whiting failure and the first whiting failure were seen about 375-390 MPa. BFR pipes and got than higher stress values than GFR pipes Burst failure for BFR pipes were observed at 614 MPa stress value and this value got higher than 35%. Elasticity module of BFR pipes was higher than GFR pipes about %13. As the average poisson s ratio of BFR pipes was 0,78, it was 0,81 for GFR pipes The usage of BFR pipes is very alternative application according to proved their mechanical properties which given above. The cost of BFR composite pipes are lower than CFR (Carbon Fiber Reinforced) composite pipes and have higher mechanical properties than CFR composite pipes and has little differences for cost each other. For gas transport line and liquid gas storage BFR composite pipes and vessels can be applied. BFR composite pipe has good chemical resistance and it can be tested for this applications. 5. ACKNOWLEDGEMENT This study is supported by Scientific Research Projects Coordinators (BAP) of Selcuk University This support is greatly appreciated. 6. REFERENCES Avci A., Şahin Ö. S., Tarakcioglu N., Fatigue behavior of surface cracked filament wound pipes with high tangential strength in corrosive environment, Composite Part A, 38, 1192-1199, 2007. Demirci M. T., Samanci A., Asilturk İ., Optimization of fatigue life parameters with Taguchi method, International Advanced Technologies Symposium (IATS 11), 16-18 May, pp453-456, Elazığ, 2011.
Gemi L., Tarakcioglu N., Akdemir A., Şahin Ö. S., Progressive fatigue failure behavior of glass/epoxy filament-wound pipes under pure internal pressure, Materials and Design, 30, 4293-4298, 2009. Martens M., Ellyin F., Biaxial monotonic behavior of a multidirectional glass fiber epoxy pipe, Composite Part A, 31, 1001-1014, 2000. Povloski D., Mislavsky B., Antonov A., Cnc cylinder manufacturers test basalt fiber, Reinforced Plastics, 36-39, 2007. Samanci A., Avci A., Tarakcioglu N., Şahin Ö. S., Fatigue crack growth of filament wound GRP pipes with surface crack under cyclic internal pressure1, J. Mater Sci., 43, 5569-5573, 2008. Samancı A., Fatigue failure behaviour of filament wound CTP pipes under internal pressure Ph.D. thesis, Dept of Mechanical Engineering, Selçuk University, Konya, Turkey, 2004. Tarakcioglu N., Gemi L., Yapıcı A., Fatigue failure behavior of glass/epoxy ± 55 filament wound pipes under internal pressure, Composite Science and Technology, 65, 703-708, 2005. Zhu l., Sun B., Hub, H., Gua B., Constitutive equations of basalt filament tows under quasi-static and high strain rate tension, Materials Science and Engineering A, 527, 3245-3252, 2010. BİYOGRAFİLER Arş. Grv. Mehmet Turan DEMİRCİ 1982 yılında Ankara da doğdu. İlk, orta ve lise tahsillerini Ankara da tamamladı. 2004 yılında Selçuk Üniversitesi Makine Mühendisliği Bölümünü birincilikle tamamladı. İZOCAM Türkiye üniversiteler arası yalıtım yarışmasında ekibiyle beraber proje dalında ikincilik aldı. 2005 yılında Selçuk Üniversitesi Teknik Eğitim Fakültesi Makine Eğitimi Bölümüne Araştırma Görevlisi olarak atandı. 2009 yılında Selçuk Üniversitesi F.B.E Makine Eğitimi ABD yüksek lisans eğitimini bitirdi ve aynı anabilim dalında doktora eğitimine devam etmektedir. Rüzgar enerjisi, aşınma, polimer malzemeler, çelik alaşımları, talaşlı imalat ve takım tezgahlarının sensörler izlenmesi alanlarında çalışmalar yapmaktadır. Yazarın nano kompozitler, kompozit borular, aşınma, talaşlı imalat ve toz metalurjisi konularında yurt içi ve yurtdışı çeşitli çalışmaları bulunmaktadır. Arş. Grv. Mehmet Turan DEMİRCİ Makine Mühendisleri Odası üyesidir. Prof. Dr. Necmettin TARAKÇIOĞLU Selçuk Üniversitesi Teknik Eğitim Fakültesi Dekanlığını yürüten Prof. Dr. Necmettin TARAKÇIOĞLU, aynı zamanda Teknoloji Fakültesi Metalurji ve Malzeme Mühendisliği Bölüm Başkanlığı idari görevine de devam etmektedir. Çalışma sahaları; metalik kompozitler, filaman sarım yöntemi ile üretim teknikleri, kompozit borular, plastik kompozitler, nanokompozitler, lazer kesme ve kaynak yöntemleri ve savunma sanayisi üzerine yapılan çalışmalardır. Evli ve üç çocuk babasıdır. Prof. Dr. Ahmet AVCI Selçuk Üniversitesi Makine Mühendisliği Mekanik anabilim dalı başkanlığı yapmakta olan Prof. Dr. Ahmet AVCI, Selçuk Üniversitesi Makine Mühendisliği Bölümü Nano Teknoloji laboratuvarı kurucusudur. İlgi alanlarını nano malzeme üretimi, hibrit nano kompozitler, nano seramikler ve hibrit kompozitler üzerine yoğunlaştırmıştır. Bu çalışma alanlarının dışında, metalik kompozitler, toz metalurjisi ve kompozit borular üzerinde de çalışmalarını sürdürmektedir. Evli ve üç çocuk babasıdır. Rifat YAKUT 1981 Kırklareli Pınarhisar Ataköy köyünde doğdu. Lise öğrenimini Lüleburgaz Teknik Lisesinde tamamladı. 2005 Fırat Üniversitesi Teknik Eğitim Fakültesi Makine Eğitimi Bölümü Otomotiv Öğretmenliği Programı bölüm birincisi olarak lisans eğitimini tamamladı. 2008 yılında Konya Selçuk Üniversitesi Fen Bilimleri Enstitüsü Makine Eğitimi Anabilim Dalı Otomotiv Eğitimi Programında yüksek lisans eğitimini tamamladı. 2009 yılında Trakya Üniversitesi Fen Bilimleri Enstitüsü Makine Mühendisliğinde doktora eğitimine başladı ve halen eğitimine devam etmektedir. 2010 yılından itibaren Hema Endüstri A.Ş. Arge merkezinde çalışmaktadır.