At present, both manual and automated processes are employed in making advanced-composite parts. Polymer A very large molecule formed by combining a large number of smaller molecules, called monomers, in a regular pattern. the chemical 2 / 10 Material name: Asplit Phenolic Resin 5469 Version #: 08 Revision date: 04-24-2019 Issue date: 04-22-2015 SDS US Wet layup The application of resin to dry reinforcement in the mold. But it’s routinely used in tiny quantities as a preservative for food and to treat various medical conditions. The reinforcing fiber imparts strength and other required properties to the composite. Bleedout The excess liquid resin appearing at the surface, primarily during filament winding. The processes vary widely in type of equipment and potential worker exposure. Tensile strength The maximum tensile stress sustained by a plastic specimen before it fails in a tension test. Resin-transfer molding (RTM) A molding process in which catalyzed resin is transferred into an enclosed mold into which the fiber reinforcement has been placed; cure normally is accomplished without external heat. Figure III:1-9. Fatigue The failure of a material's mechanical properties as a result of repeated stress. Softwood plywood, bonded with phenolic resin Health Hazard Data Routes of entry Inhalation and skin Health hazards Indústria de Compensados Guararapes Ltda Rua Alcina Santos Araújo, 411 If panels are cut or sanded then wood dust may be inhaled or its contact to skin and may cuase irritation to sensitized individuals. Dry winding A type of filament winding in which preimpregnated roving is used. Release agents Materials that are used to prevent cured matrix material from bonding to tooling. Visual disturbances may also occur. as a cleaning agent for removing residue from the process equipment. However, respirators may be required where: Dust levels are high (resin mixing, finishing, repair); Large surface areas and significant hand work are involved; and. Anisotropic The tendency of a material to exhibit different properties in response to stresses applied along axes in different directions. At normal temperatures these resins do not give off vapour but when they are heated, formaldehyde is evolved which is a potential respiratory sensitiser and has been shown in experiments to cause cancer in animals. Other solvents that may occasionally be used are: Heated curing areas including autoclaves; following the proper procedures for production, process and control equipment; proper use, maintenance, and cleaning of personal protective equipment; periodic inspection and maintenance of production, process and control equipment; and. Good workplace controls are essential in controlling exposure to process materials. Since these compounds act as catalysts for the reaction, they must contain active sites on their molecules. The form around which resin-impregnated fiber or tape is wound to form structural shapes or tubes. Crimp A fiber's waviness, which determines the capacity of the fiber to cohere. The technology of advanced composites manufacture is continually evolving, and field personnel will learn here what to expect in these processing facilities in the way of materials handled, manufacturing methods, machinery, potential worker exposures, and other relevant health and safety information. Acetone is a popular solvent used for cleanup and may be found around the workplace in containers for this purpose. Fabric, woven A material constructed of interlaced yarns, fibers, or filaments. Both thermoset and thermoplastic systems will be discussed in more detail in. 34 (1995) 3096-3101. Several solvents may be used in any one composite process. Film adhesive An adhesive in the form of a thin, dry, resin film with or without a carrier, commonly used for adhesion between layers of laminates. The resin systems used to manufacture advanced composites are of two basic types: thermosetting and thermoplastic. Buckling (composite) A failure usually characterized by fiber deflection rather than breaking because of compressive action. Draft angle A mandrel's taper or angle for ease of part removal. Environmental Effects NA Physical and Chemical Hazards Free phenol is hazardous Typically they are high-viscosity liquids. LABEL ELEMENTS According to the Regulation (WE) 1272/2008: Pictograms: Signal Word: DANGER Hazard statements: H315 Causes skin irritation. Practically all glass fibers for composite reinforcement are greater than six microns in diameter. Exposure to the high-melting solids like trimellitic anhydride and tetraphthalic anhydride can cause respiratory sensitization. Advanced composites have been identified as an important growth sector in U.S. manufacturing. Polyacrylonitrile (PAN) A product used as a base material in the manufacture of certain carbon fibers. Fiber placement A continuous process for fabricating composite shapes with complex contours and/or cutouts by means of a device that lays preimpregnated fibers (in tow form) onto a nonuniform mandrel or tool. Although they came into existence at the very start of the age of polymers, they continued to be developed into more and more applications. (The terms graphite and carbon are often used interchangeably.) With respect to the phenol-formaldehyde resins, the well-known hazards of both phenol and formaldehyde must be protected against. Circuit One complete traverse of the fiber feed mechanism of a filament-winding machine. DOT ID & Guide. www.OSHA.gov. It is not however a proven human carcinogen. Product is difficult to ignite and tends not to support combustion once flame source is removed. Thermoset resins require addition of a curing agent or hardener and impregnation onto a reinforcing material, followed by a curing step to produce a cured or finished part. Usually includes application of heat to trigger curing of the resin. Hazard classification & labelling Hazard classification and labelling. Stress The internal force that resists change in size or shape, expressed in force per unit area. The reinforcement is saturated by dipping through the liquid resin (solution form, see Figure III:1-1) or by being impregnated through heat and pressure (hot melt form, see Figure III:1-2). Vacuum Bagging and Autoclave. Airborne fiber of this diameter does not reach the alveoli and is nonrespirable. Biaxial winding A type of filament winding in which the helical band is laid in sequence, side by side, with no crossover of the fibers. Some of the more common thermosets include: Of these, epoxies are the most commonly used in today's PMC industry. Tooling resins Plastic resins, chiefly epoxy and silicone, that are used as tooling aids. Occupational Safety and Health Administration, Department of Labor, Final Rule: Occupational Exposure to 4,4'Methylenedianiline (MDA) for 29 CFR Parts 1910 and 1926. Amide hardeners generally have only a slight irritant effect. These materials do not react with the resin but are an integral part of the advanced composite system. Bias fabric A fabric in which warp and fill fibers are at an angle to the length. The basic epoxy compounds most commonly used in industry are the reaction product of epichlorohydrin and bisphenol-A. Curing agents, or hardeners, used with the epoxy resins are mostly amines, amides, or anhydrides. H319 Causes serious eye irritation. Phenolic and amino resins are another group of PMC resins. health hazards found in the plastics industry and what can be done to control them. More dust is usually generated in finishing and repair processes since large surface areas are involved. There are essentially no permeation data available for chemical mixtures. Several other types of curing agents are also used in the advanced composite industry. Bidirectional laminate A reinforced plastic laminate in which the fibers are oriented in more than one direction in the plane of the laminate. The FR 57(154): Another of the amines, DDS, has a significant amount of toxicological data as its pharmaceutical grade, Dapsone. Symptoms may include irritation, redness, scratching of the cornea, and tearing. Thus the hazard information for all products used in the process must be considered when evaluating potential exposures. Bearing strength The maximum bearing stress that will not cause a composite to fail when applied through a cylindrical fastener surface. Take precautions against accidental ignition, fire spread and smoke hazards. However, like other hydrocarbons, benzene can cause chemical pneumonia if its liquid form is aspirated in to the lungs. Debond An unplanned nonadhered or unbonded region in an assembly. While the polyols are relatively innocuous, the isocyanates can represent a significant respiratory hazard as well as a dermal hazard. While aerospace is the predominant market for advanced composites today, the industrial and automotive markets will increasingly see the use of advanced composites toward the year 2000. Drape The ability of prepreg to conform to the shape of a contoured surface. Filament winding A process for fabricating composites in which continuous reinforcing fibers, either preimpregnated with resin or drawn through a resin bath, are wound around a rotating, removable mandrel. Technical literature including MSDS's from the solvent supplier should be consulted about these or any chemicals used with advanced composites. However, they do have the potential to cause eye, skin, and upper respiratory tract irritation as a result of the mechanical properties of the fibers. Seven manufacturing processes are covered, along with two preliminary processes and two finishing processes. The aromatic amine curing agents are particularly difficult to protect against. Phenolic resins boards are a new substitute of wood in highly aggressive environments. However, in the case of resins and curing agents, not much data are available. Selection of the proper protective materials should be based on permeation data, if available. Unidirectional Refers to fibers that are oriented in the same direction, such as unidirectional fabric, tape, or laminate, often called UD. Bond strength The amount of adhesion between bonded surfaces. Knop, A. and L. A. Pilato, Phenolic Resins Chemistry, Applications, and Performance, Springer-Verlag, Berlin, 1985. Several of the processes are automated; however, some are manual and require worker contact with the part during manufacture. Phenolic and amino resins are another group of PMC resins. Engineered Materials Handbook, Vol. Federal Register 57(154): 35630 (August 10, 1992), [Adapted from Advanced Composites Magazine, 1992 Bluebook, Edgell Plastics Publications]. Additives Ingredients mixed into resin to improve properties. They are typically supplied as nonreactive solids (no chemical reaction occurs during processing) and require only heat and pressure to form the finished part. MDA is an animal carcinogen and a suspect human carcinogen by any exposure route: ingestion, inhalation, or dermal. However, potential for dermal exposure is frequently high. The three basic types of fiber reinforcement materials in use in the advanced composite industry are: The most commonly used reinforcement materials are carbon/graphite fibers. Butt joint A joint in which parts are joined with no overlap. The information presented necessarily makes reference to industrial hygiene and safe work practices, but this manual is not intended to provide comprehensive guidelines for assessing compliance with regulations. Since the advanced composite industry is relatively new and still developing, other processes may be developing or changing to meet new performance requirements. Reinforcement A material added to the matrix to provide the required properties; ranges from short fibers through complex textile forms. Depending on which specific phenolic is being worked with, one or more of the components could contain aromatic or aliphatic amine compounds that are skin, eye and even respiratory irritants. Related Pages. Permeation data are available for many industrial chemicals, especially solvents. Thermosetting resins predominate today, while thermoplastics have only a minor role in advanced composites manufacture. Fracture toughness A measure of the damage tolerance of a material containing initial flaws or cracks. Cure temperature The temperature at which a material attains final cure. Interlaminar Existing or occurring between two or more adjacent laminae. In general, studies on composite dusts indicate that: The dusts are particulate in nature and usually contain few fibers; The dusts are thermally stable up to 250 °C and exhibit a high degree of cure; and. Still another may be used for cleanup. Individual Protection Measures, Such as Personal Protective Equipment Unlike the thermosets, the thermoplastics can usually be reheated and reformed into another shape, if desired. Occupational Safety and Health Administration, Technical Equipment: On-site Measurements, Polymer Matrix Materials: Advanced Composites. The selection of reinforcement material is based on the properties desired in the finished product. It is a resource guide to help plastics workers and their unions understand the nature and extent of toxic exposures in the production of plastics, and what measures can be taken for a cleaner and healthier workplace. The various types of workplace controls described below may typically be found in the advanced composite workplace. Wrinkle An imperfection in the surface of a laminate that looks like a crease or fold in one of the outer layers; it occurs in vacuum bag molding due to improper placement of the bag. 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