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The aim of this research was to investigate the potential use of recycled glass fibre composite materials as a replacement for virgin reinforcing materials in new thermoset composites. Specifically the closed-loop mechanical recycling of composites used heavily in the automotive sector known as dough and sheet moulding composites, DMC and SMC respectively, are investigated. The recycling of glass reinforced thermoset polymer composite materials has been an area of investigation for many years and composites used in the automotive industry are of particular interest due to legislative and social pressures on the industry. The mechanical recycling process and then collection of useful fibrous grades of recycled materials, recyclate, by a novel air separation technique were investigated first. The properties of these recyclate fibres were characterised and compared directly with the properties of virgin glass fibres they were to be used to replace. Single fibre tensile tests were employed to compare the strengths of the fibres and single fibre pull-out tests were used to investigate the strength of the interface between the fibres and a polyester matrix. These tests showed the recyclate fibres to be weaker and have a poorer interface with the polyester matrix than the virgin glass fibres. Understanding the properties of the recyclate materials meant their reformulation into new composites could be carefully considered for the production of new high performance materials. Two grades of the collected recyclate materials were then reformulated in to new DMC and SMC composites, replacing percentages of the virgin glass fibre reinforcement. The mechanical properties of the resulting manufactured composites were characterised throughout for direct comparison against one another and an unmodified control material, using both three-point flexural tests and Charpy impact tests. Through the modification of existing manufacturing techniques and the development of novel production equipment it has been possible to successfully manufacture both DMC and SMC composites with the recyclate materials used to replace virgin glass fibres. Virgin glass fibres have successfully been replaced by recyclate materials without disrupting standard production techniques and with minimal reduction of the mechanical properties of the resulting composites. As the loadings of recyclate materials used were greatly increased both the flexural and impact strengths were significantly degraded and it was found that chemical modification of the composite could be used to improve these formulations. It has been shown that the recyclate materials should be considered and treated as a distinct reinforcing ingredient, separately from the remaining virgin glass fibres.

Glass-fibre reinforced plastic pipes are widely used to convey fluids for various purposes. They offer a number of distinct advantages over conventional metals, such as high specific strengths, high specific moduli, superior corrosion resistance and low coefficient of thermal expansion. However, their behaviour under lateral quasi-static and impact loading are still not well known. The research programme described in this thesis was designed to characterise the performance of 55° winding angle GRP pipes, subjected to lateral quasi-static and impact loading. Two approaches: experimental tests and finite element analysis, were used to investigate the behaviour of the GRP pipes. The experimental investigation was started with diametral compression of short GRP pipes to examine the structural behaviour and failure mechanisms. Subsequently, lateral indentation tests were conducted on rigid-foundation supported or simply supported specimens using two different indenter geometries: line-ended and flat-ended. Furthermore, low-velocity impact tests were performed under similar conditions as those for indentation tests in order to characterise the response of the GRP pipes and to identify the correlation between the two forms of loading. The pipes exhibited multi-mode failure mechanisms, resin cracks, delaminations and fibre breakage. It is found that delamination, which resulted in significant loss in stiffness and strength, was the most significant mode of failure for the GRP pipes. A good correlation in behaviour was identified between quasi-static indentation and its energy equivalent low-velocity impact when the global bending stiffness of the GRP specimens were high. Specimens with span S 10.5D i, where Di is the internal diameter of the pipe, are considered to have high bending stiffness, while simply supported specimens with S10.5D i have low bending stiffness. Irrespective of the support conditions and loading type, specimens with high bending stiffness followed a failure mechanism sequence: local resin failure, delamination and the fibre breakage. However, the large global bending experienced by low bending stiffness specimens resulted in a change of failure mechanism, only local damage and surface tensile cracks were observed.

This work consists of an investigation into the microstructure and mechanical behaviour of glass fibre reinforced polyester resin beams. The volume fraction occupied by glass fibres was 20-30%, which is that typically used in boat building. The beams tested were all unidirectional, with fibres oriented parallel or perpendicular to the long axis of the beam. Various techniques have been developed which may be applicable to other composite materials. The microstructure of the beams was investigated by observation of cross-sections using a Quantimet 720 Image Analysing Computer. Volume fractions and the distribution. of fibre cross-sectional areas were measured. Methods have been developed for the quantitative definition of the microstructure, in terms of the fibre arrangement. Cracks were grown in four-point flexural loading while monitoring acoustic emission. The acoustic emission circuit was built in the laboratory, and designed to monitor fibre failures only, one count being associated with one fibre failure. The processes of crack growth were further investigated by observation of fracture surfaces using a scanning electron microscope and measurement of crack profiles. The factors controlling the processes of crack growth have been elucidated. The material condition was monitored by specific damping capacity measurements. A free-free rig with excitation at the ends of the beam was developed. In addition measurements were made using a cantilever rig. Simple analyses involving the solution of the classical wave equation were carried out; a receptance analysis was also developed which allows the undamaged and cracked portions of the beam to be separated in the analysis. Invisible cracks, which had been indicated by acoustic emission, were successfully detected in both rigs. The correlation between recorded acoustic emissions and specific damping capacity measurements supports the validity of both techniques. Some correlation between properties and measured microstructures has been obtained here. These quantitative methods for the measurement of the microstructure of composite materials should prove very useful in a wide range of applications.

Glass Fibre Reinforced Polymer (GFRP) bars have been developed as an alternative to steel reinforcement for various structural concrete applications. Due to their non-corrossive nature, they are particularly suited for harsh environments where steel reinforcement is prone to corrosion. The purpose of this research is to determine the feasibility of GFRP reinforcing bars as concrete bridge deck reinforcement for locations, such as coastal New Zealand, where the non-corrosive benefits of GFRP may offer an alternative to traditional mild steel reinforcement. GFRP use as structural reinforcement may offer life-cycle cost benefits for certain structures as maintenance to repair corroded reinforcement is not necessary. The use of GFRP reinforcement in a New Zealand design context was investigated to directly compare the structural performance of this alternative reinforcing product. Mateen-bar, manufactured by Pultron Composites Ltd, is the GFRP reinforcing bar used in the experimental tests. Experimental investigation of tensile properties of GFRP bar samples was carried out to understand the mechanical behaviour of GFRP reinforcement and validate the manufacturer’s specifications. This series of tests highlighted the complexities of carrying out tensile testing of FRP products, due to the inability to grip the GFRP directly in a testing machine without crushing the specimen. Two phases of full-scale tests were carried out to compare the performance of bridge deck slabs reinforced with typical mild steel and GFRP reinforcing bar. This experimental testing was different to most existing research on GFRP reinforced slab performance as it did not compare the performance of a GFRP reinforcing bar area equivalent to steel, but was designed in such a way as to dependably give the same moment capacity of the steel reinforced slab design. This incorporated the recommended limit of 20% of design stress given by the manufacturer which led to an apparent over-reinforced section for the GFRP slab design. The aim of the experiments was to investigate the comparative performance of a typical New Zealand bridge deck design and a GFRP reinforced equivalent designed in such a way as is currently recommended by the manufacturer. The over-reinforcement lead to differences in conclusions drawn by other authors who have studied GFRP reinforced slab behaviour. Both flexural and concentrated loading (simulating vehicle loading) tests were carried out on both the steel and GFRP reinforced slab designs. Due to over-reinforcement the GFRP slab was considerably stiffer and stronger than the steel design, indicating that serviceability issues are unlikely to be as much of a design issue as existing literature would suggest. Deflection prediction models generally underestimate the strength of over-reinforced sections. All slabs failed in punching shear under concentrated loads, indicating that punching shear may be a critical failure mechanism for GFRP reinforced slabs Based on the findings from the extensive experimental phases, a set of design recommendations were made to further improve the potential for GFRP to be used for bridge deck design in a New Zealand context.

No description available.

No description available.

No description available.

lass fibre reinforced plastic (GRP) structural profiles, in standard shapes and sizes are now being commercially manufactured by the process of pultrusion. GRP profiles are light weight, posses higher specific strengths and are more durable than the conventional metal or concrete counterparts. GRP pultruded profiles have open or closed cross-sections comprising thin composite walls of low elastic moduli. Stability failure has been identified as the main cause of failure for these profiles when subjected to compressive stresses, as it may occurs at stresses much lower than the ultimate strengths. Therefore, the load carrying capacities of composite compression members mainly depends upon stability criteria. The conventional stability analyses for the prediction of buckling loads are not considered adequate as the GRP material is orthotropic and its behaviour is different from steel (non-yielding). The existing guidance for the design of composite members under compression ignores the presence of geometrical imperfections inherited in the pultruded profiles, whilst, experimental evidence suggests considerable loss of stiffness due to the imperfections particularly in the intermediate column heights. The design guidance provided by the manufacturers gives empirical equations based on data obtained from experiments on specified profiles. A universal design curve based on the experimental results of concentrically loaded GRP columns has been developed and presented. However, conducting a vast experimental study is not always feasible. The need to develop a procedure, predicting failure load numerically for the development of a design curve for GRP columns has been recognised. Two GRP box-sections (closed square cross-sections) have been investigated for failure/buckling loads using experimental and numerical methods. In the experimental phase, specimen columns of various heights have been concentrically loaded in compression to measure the failure loads. Experimental results have been compared with the theoretical predictions made using classical methods and the equations given by the design manuals. Based on the experimental and analytical failure loads, an experimental design curve has been derived. In the numerical study, 3-dimensional full scale finite element models representing experimental configuration of the composite columns, have been analysed using both linear and nonlinear solutions. Imperfections of known amplitudes have been included parametrically to establish the sensitivity of the failure loads towards imperfections. Imperfect model have been calibrated for the estimation of imperfection amplitude present in the profiles using experimental data. Using the numerical and analytical data, a design curve has been derived establishing interaction coefficients for each profile. The numerical design curve is compared with the experimental design curve for the validation of the numerical procedure adopted in this study. Effects of perforations (circular holes) on the buckling stiffness of GRP box-section columns have also been investigated. Holes are drilled in the walls of profiles and tested experimentally to measure the loss in the buckling loads. Finite element models of columns with holes have been developed and analysed for buckling loads. Comparisons of experimental and numerical results are plotted. For use in the numerical representation of the composite columns, mechanical properties of the orthotropic GRP material of the both sections have been established analytically and experimentally. In-plane shear properties have been measured by physically testing standard sized coupons, extracted along the length of profiles. However, short coupons were available in the transverse directions due to dimensional constraints. Short coupons, similar in geometry to the standard coupon, but smaller in size, have been validated for performance using finite element analyses and comparing the outcomes with the models of standard coupons. Both standard and short coupons have been used for the experimental measurement of the in-plane shear properties. Compression properties have also been measured experimentally. Ultimate failure/buckling loads of the composite columns depend upon their heights, material properties, and the cross-sectional dimensions. These factors have been combined into one characteristic parameter 'λ', the slenderness ratio. As the later two factors are constant for a particular box-section profile, the ultimate loads depend upon column heights. Four types of failure modes; global, local, modal interaction and material failure have been observed. The loss in the buckling stiffness is minimal for smaller circular holes, provided the interval between holes is not less than 20 times the diameter of the holes. For bigger holes and an inter hole spacing of 10time the diameter, a loss of 30% have been measured. Finite element representation of pultruded columns adequately predicted the numerical failure loads and failure modes for most of the column heights.

Composite materials have become viable alternatives to traditional engineering materials for many different product categories. Liquid transfer moulding (LTM) processes, specifically resin transfer moulding (RTM), is a cost-effective manufacturing technique for creating high performance composite parts. These parts can be tailor-made to their specific application by optimizing the properties of the textile preform. Preforms which require little or no further assembly work and are close to the shape of the final part are critical to obtaining high quality parts while simultaneously reducing labour and costs associated with other composite manufacturing techniques. One type of fabric which is well suited for near-net- shape preforms is stitched non-crimp fabrics. These fabrics offer very high in-plane strength and stiffness while also having increased resistance to delamination. Manufacturing parts from these dry preforms typically involves long-scale fluid flow through both open channels and porous fibre bundles. This thesis documents and analyzes the flow of fluid through preforms manufactured from non-crimp fabrics featuring through-thickness stitches. The objective of this research is to determine the effect of this type of stitch on the RTM injection process. All of the tests used preforms with fibre volume fractions representative of primary and secondary structural parts. A series of trials was conducted using different fibre materials, flow rates, fibre volumes fractions, and degrees of fibre consolidation. All of the trials were conducted for cases similar to RTM. Consolidation of the fibres showed improvements to both the thoroughness of the filling and to the fibre volume fraction. Experimentally determined permeability data was shown to trend well with simple models and precision of the permeability data was comparable to values presented by other authors who studied fabrics which did not feature the through-thickness stitches.