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Experimental Analysis of E-Glass /Epoxy & E-Glass /polyester Composites for

Auto Body Panel

Article · May 2015

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American International Journal of Available online at [Link]
Research in Science, Technology,
Engineering & Mathematics
ISSN (Print): 2328-3491, ISSN (Online): 2328-3580, ISSN (CD-ROM): 2328-3629
AIJRSTEM is a refereed, indexed, peer-reviewed, multidisciplinary and open access journal published by
International Association of Scientific Innovation and Research (IASIR), USA
(An Association Unifying the Sciences, Engineering, and Applied Research)

Experimental Analysis of E-Glass /Epoxy & E-Glass /polyester Composites

for Auto Body Panel
Esmael Adema*, Er. Mukesh Didwaniab*, Gurala Muralidhar Reddyc, Ermias G. Korichod
a
Lecturer, Mechanical Department, Adama Science & Technology University, Adama, ETHIOPIA.
b
Assistant Professor, Mechanical Department, Adama Science & Technology University, Adama, ETHIOPIA.
c
Lecturer, Mechanical Engineering Department, Adama Science & Technology University, Adama, ETHIOPIA.
d
Research Associate, Mechanical Engineering, Michigan State University, Composite Vehicle Research Center,
2727 Alliance Drive, Lansing, MI 48910. USA.

Abstract: In this paper Experimental characterization of the mechanical properties of E-glass/Epoxy & E-
glass/Polyester composite was conducted. The objectives of this paper is to present processing techniques
of specimen preparation, conducting experiment to obtain mechanical properties and conduct experimental
observation using Scanning Electron Microscopy (SEM) to know inhomogeneity, porosity and fracture
behavior. The effect of strain rate on E-glass/epoxy and E-glass/polyester has been investigated &
experimentation was performed to determine property data for material specifications. E-glass/polyester
laminates were obtained by compression molding process and E-glass/epoxy laminate by hand lay-up
vacuum assisted technique. The laminates were cut to obtain ASTM standards. This investigation deals with
the testing of tensile, compression, shear and flexural strength on a universal testing machine. The graphs
that are obtained from the tests were documented. This research indicates that the mechanical properties
are mainly dependent on the strain rate.

Key words: Characterization, strain rate, ASTM, Mechanical tests, SEM, Laminate

I. Introduction
In order to conserve natural resources and economize energy, weight reduction has been the main focus of
automobile manufacturers in the present scenario. Weight reduction can be achieved primarily by the
introduction of better material, design optimization and better manufacturing processes. Even though there are
several factors that influence the entire product development process to realize a lightweight vehicle, from the
point of view of vehicle structural design, the main governing criteria for material selection are stiffness and
strength properties that will determine the overall performance of vehicle during static and dynamic
loading conditions. [1, 2].
In order to estimate strength and stiffness, structural materials are subjected to mechanical testing such as
tensile, compression, shear and flexural tests. Tests aimed at evaluating the mechanical characteristics of fibrous
polymeric composites are the very foundation of technical specification of materials and for design purposes,
in order to develop numerical and experimental models. The mechanical testing of composite structures to
obtain parameters such as strength and stiffness is a time consuming and often difficult process. It is, however,
an essential process, and can be somewhat simplified by the testing of simple structures, such as flat coupons.
The data obtained from these tests can then be directly related with varying degrees of simplicity and accuracy
to any structural shape, [3, and 4].
George C. Jacob [Link]. [5] Summarizes a detailed review of strain rate effects on the mechanical properties of
polymer composite materials. An attempt was made to present and summarize much of the published work
relating to the effect of strain rate studies done in the past on the tensile, shear, compressive, and flexural
properties of composite materials. It can be inferred from this detailed review that the effect of varying loading
rate on this mechanical properties of fiber-reinforced composite materials has been investigated by a number of
workers and a variety of contradictory observations and conclusions have resulted. Hence, more work must be
done in the pursuit of eliminating all disagreements that currently exist regarding the effect of loading rate on
the tensile, compressive, shear, and flexural properties of fiber-reinforced polymer composite material.
The effect of strain rate on the tensile properties of a glass/epoxy composite was investigated by Okoli and
Smith [6]. Tensile tests were performed on a glass epoxy laminate at different rates (1.7 x10-2 -2000 mm/s). The
tensile strength of the composite was found to increase with strain rate. In other studies the effects of strain rate

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 Adem et al., American International Journal of Research in Science, Technology, Engineering & Mathematics, 10(4), March-May, 2015,
pp. 377-383

on the tensile [7, 8], shear, and flexural properties of glass/epoxy laminate was investigated by Okoli and Smith.
Tensile modulus increased by 1.82%, tensile strength increased by 9.3%, shear strength increased by 7.06%, and
shear modulus increased by 11.06% per decade increase in log of strain rate.
The paper tries to fill the gap which occurs on the composite manufacturer, Dejen Aviation Industry, here in
Ethiopia by conducting experimental tests and presents the effect of strain rate on the mechanical behavior of E-
glass/epoxy and E-glass/Polyester composite under quasi-static loading conditions by varying the strain rate in
order to get the mechanical properties, this tests includes tensile, compression, flexural and shear tests.

II. Materials and Experimental Test Conditions

The raw materials used in this work are: woven bidirectional E-glass fibers, Epoxy Resin with brand name of
SYSTEM #2000 EPOXY RESINS with SYSTEM #2060 HARDNER. The ratio of net epoxy resin and
hardener was specified according to the manufacturer’s manual, (3 part epoxy to 1 part hardener by volume or
100 part epoxy to 27 part hardener by weight). Unsaturated Polyester with brand name of Part # - 83 with
catalyst brand name of #69 MEKP. The ratio of catalyst to resin is 1.25% by weight with #69 MEKP. All the
materials are obtained from Dejen Aviation Industry (DAVI), Bishoftu, Ethiopia.
Table 1. Fiber and matrix volume contents of the composite laminate
Manufacturer’s data and Measured values Calculated Value
Glass fiber density 2.6 gm/cc Glass fiber volume 375.77 cc
Epoxy Matrix density 1.11 gm/cc Epoxy Matrix volume 333.33 cc
Polyester Matrix density 1.2 gm/cc Polyester Matrix volume 574.16 cc
Glass fiber weight 977 gm Fiber volume ratio for E-glass/Epoxy 53%
E-glass/Epoxy Composite Fiber volume ratio for E-glass/Epoxy 53%
weight 1347 gm
E-glass/Polyester Fiber volume ratio for E-glass/Polyester 40%
Composite weight 1666 gm
Epoxy Matrix volume ratio 47%
Polyester Matrix volume ratio 60%
Fiber weight ratio for E-glass/Epoxy 72.5%
Epoxy Matrix weight ratio 27.5%

The above results were obtained by taking technical data about E-glass fiber, epoxy and polyester resin from
manufacturer’s manual and taking technical measurement on mass of fiber, composite as well as equations used
to determine fiber volume ratio from reference [9], the unknown values (fiber volume fraction) were evaluated.
A. Composite sample fabrication process
Composite laminates are formed by assembling different plies with different angles and orientations. Generally,
in this work 5 plain woven plies are used for Tensile & shear specimens’ preparation and 10 plies are used for
compression & bending test specimens. The stacking sequence of laminate used with its respected angle is
shown in fig. 1.
Fig. 1 Stacking Sequences of the laminate

Here, two types of manufacturing methods are used in order to fabricate the samples:
1) Compression Molding
This type of manufacturing method is chosen for E-glass/Polyester composite samples due to:
 Polyester resin has relatively high viscosity which can damage the vacuum pump when vacuum
bagging is used.
 This method is practiced and used in manufacturing of automotive components at Dejen Aviation
Industry.
 Compression molding uses fewer components than vacuum bagging technique.
2) HLVA
Hand lay-up Vacuum assisted technique (HLVA) as shown in fig. 2, for E-glass/Epoxy composite samples. This
is basically an extension of the hand lay-up process where pressure is applied to the laminate once laid-up in
order to improve its consolidation. This is achieved by sealing a plastic film over the hand laid-up laminate and
on to the tool. The air under the bag is extracted by a vacuum pump and thus up to one atmosphere of pressure

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 Adem et al., American International Journal of Research in Science, Technology, Engineering & Mathematics, 10(4), March-May, 2015,
pp. 377-383

can be applied to the laminate to consolidate it. The equipment’s used are: Rotary vacuum pump, with Model
No: 2TW-4C, Capacity: 8cfm, Vacuum: 6.7×10-2Pa, Power: 220-240v/50Hz, Peel Ply (Release Fabric),
perforated plastic film, Pressure fabric (breather), Vacuum nylon (vacuum bag), Mastic sealant (Vacuum tape),
Vacuum bagging mold, Mold Release, paste wax.
Fig. 2 techniques of composite manufacturing used in this paper (a) Hand lay-up technique (b) HLVA
technique

B. Specimens Geometry and Dimensions

The geometry of each of loading configuration for E-glass/epoxy & E-glass/Polyester composite material is
shown in fig. 3 below and is based on American Society of Testing & Materials (ASTM), [10-14].
Fig. 3 Test Specimen Dimensions (a) Tensile Test Specimen (b) Compression Test Specimen (c) In plain
Shear Test Specimen (d) Flexural strength/3-point test/ dimensions and set up in 3D drawing

C. Testing Conditions
Three specimens for each test configuration were tested, in order to show the repeatability of the results through
which minimizing the experimental errors, under tensile, compression, flexural and in plain shear loading with a
Computer electro-hydraulic universal testing machine (model: WAW-600) with a capacity of 600 kN, precision
grade is 0.5 with 0.01 - 500 mm /min test speed and manufactured in Shanghai Hualong Testing Instruments
[Link], China. Test world data acquisition software is used to acquire data from the machine during testing.
Each specimen was clamped by means of hydraulic wedge grips. The machine was equipped with a standard
load cell and a crosshead displacement measuring device. The experiment was conducted with varying strain
rate values in quasi-static condition at room temperature (250C). The strain rate value, crosshead speed, the total
amount of specimen used and repetition of specimen for these experimental tests are shown in table 2 below.
Strain Rate = (Cross head speed)/(Gage Length) =V(mm/min)/(mm)
Table 2: Test Condition Parameters
Strain Rate Tensile and shear Test Compression Test Flexural Test Repetition
Value (S-1) Crosshead Crosshead Value Crosshead Value for all tests
speed speed (S-1) speed (S-1)
(mm/min) (mm/min) (mm/min)
Strain rate 1 3.33E-5 0.2 0.2 1.66E-4 0.2 3.175E-5 3
Strain rate 2 3.33E-4 2 2 1.66E-3 2 3.175E-4 3
Strain rate 3 3.33E-3 20 20 1.66E-2 20 3.175E-3 3
Required 2x3x3=18 specimen 3x3=9specimen 3x3=9specimen
Specimen

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 Adem et al., American International Journal of Research in Science, Technology, Engineering & Mathematics, 10(4), March-May, 2015,
pp. 377-383

Morphology of E-glass/Epoxy before test and the interfacial adhesion between fiber–matrix and tensile fracture
after test was examined by scanning electron microscopy (SEM), Model: EM-30, serial number: CXS-3TAH-
113031 with mark COXEM, which is shown in fig. 4 below.
Fig. 4: (a) Scanning Electron microscopy (b) Ion Gold Coater (c) gold coated specimen

III. Experimental Results and Discussion

A. Tensile test
Fig. 5 effect of strain rate on tensile strength of E-glass/Epoxy and E-glass/Polyester composites
350 350
0.000166 s-1
0.0000333 s-1
0.00166 s-1
300 0.000333 s-1 300
0.00333 s-1
0.0166 s-1
Engineering Stress [MPa]
Engineering Stress [MPa]

250 250

200 200

150 150

100 100

50 50

0 0
0 0.01 0.02 0.03 0.04 0.05 0.06 0 0.01 0.02 0.03 0.04 0.05 0.06
Engineering Strain [mm/mm] Engineering Strain [mm/mm]

(a) E-glass/Epoxy (b) E-glass/Polyester

Fig. 5 (a) above shows tensile strength of E-glass/Epoxy composite as a function of strain with different quasi-
static strain rate. The test result shown is based on the average value of three specimens for each strain rate
value. The result clearly shows when the strain rate is increased the tensile strength of the material was
decreased. The percentage decrement of tensile stress is 3.06% and 15.24% for the first and second speed
respectively. The effect of strain rate on tensile strength of E-glass/Polyester composite is shown in figure 5 (b).
The given graph indicates the tensile strength of E-glass/Polyester composite was increased with the increase of
strain rate. The percentage increment in tensile strength of the given composite is 0.514% and 11.98% for the
first and second speed respectively. Regarding tensile failure mode, E-glass/Epoxy composite showed
significant failure mode variation with increasing strain rate. As shown in Fig. 6 (a) limited damage within
the gage length near grip area at the first speed and further strain rate increment changed the failure mode by
extending the damage area to the center gage length and create fiber pullout. For example, as shown in Fig. 6
(a), at 0.000333 s-1 strain rate (TER3-02), excessive deboning between the fiber and matrix was
exhibited. On the other hand, E-glass/Polyester composite showed grip area failure, as shown in Fig. 6 (b).
Fig. 6 Tensile Failure modes (a) E-glass/Epoxy composite (b) E-glass/Polyester Composite

B. In-Plane shearing Test

Fig. 7 (a) demonstrates quasi static strain rate effects on shear strength of E-glass/Epoxy composites. The test
result shown is based on the average value of three specimens for each strain rate value. It can be clearly seen
that the sear strength is increasing with the increase of strain rate. The percentage increments for the first two

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 Adem et al., American International Journal of Research in Science, Technology, Engineering & Mathematics, 10(4), March-May, 2015,
pp. 377-383

speeds are 0.44% and 19.93%. The effect of strain rate on shear strength of E-glass/Polyester is displayed in
figure 7 (b) below. The result shows that the shear strength shows a decreasing trend with an increasing strain
rate but, the effect of insignificant. The percentage decrement in shear strength of the given composite is 5.09%
and 3.59% for the first and second speed respectively. The application of composite materials in mechanical
engineering is limited by poor transverse and shear properties of unidirectional composites, which raise concern
about their impact behavior [5].
Fig. 7 In-plane shear strength of (a) E-glass/Epoxy & (b) E-glass/Polyester composites
80
80
0.0000333 s-1 0.0000333 s-1
70 0.000333 s-1 70 0.000333 s-1
Engineering Shear Stress [MPa]

Engineering Shear Stress [MPa]

0.00333 s-1 0.00333 s-1
60 60

50 50

40 40

30 30

20 20

10 10

0 0
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08
Engineering Shear Strain [mm/mm] Engineering Shear Strain [mm/mm]

Regarding in-plane shear failure mode, E-glass/Epoxy composite showed significant failure mode variation
with increasing strain rate. As shown in Fig. 8 (a) limited damage within the gage length near grip area in the
first strain rate and further strain rate increment changed the failure mode by extending the damage area to the
center of gage length and create fiber pullout. For example, as shown in Fig. 8 (a), at 0.000333 s-1 strain rate,
excessive deboning between the fiber and matrix was exhibited. On the other hand, E-glass/Polyester
composite showed grip area failure, as shown in Fig. 8 (b)
Fig. 8 In-plane Shear Failure modes (a) E-glass/Epoxy composite (b) E-glass/Polyester Composite

C. Compression Test
The compression test results obtained from this work are not much satisfactory because the universal testing
machine available in Mechanical and Industrial engineering school of AAIT material testing laboratory is not
complete especially for this tests. For example there is no grip for compression tests. Due to this the shape of
compressive stress-strain curve is unusual and the maximum value of compressive strength is lower.
Fig. 9 Compressive strength of (a) E-glass/Epoxy & (b) E-glass/Polyester composites
120 120
0.000166 s-1 0.000166 s-1
100 0.00166 s-1 100 0.00166 s-1
Compressive Stress [MPa]

0.0166 s-1 0.0166 s-1

Compressive Stress [MPa]

80 80

60 60

40 40

20 20

0 0
0 0.02 0.04 0.06 0.08 0.1 0 0.02 0.04 0.06 0.08 0.1
Compressive Strain [mm/mm] Compressive Strain [mm/mm]

Fig. 9 (a) presents quasi-static strain rate effect on compressive strength for E-glass/epoxy composite as a
function of strain rate. The test results presented are based on average values of three specimens for each strain
rate value. It can be clearly seen that the compressive strength follows an increasing trend with the increase of
strain rate for the first two speeds and decreases. The percentage increment and decrement for the first two strain
rate values are 26.42%and. 6.53% respectively. The effect of strain rate on compressive strength of E-
glass/Polyester composite is shown in fig. 9 (b). The given graph indicates the compressive strength of E-
glass/Polyester composite was increased with the increase of strain rate. The percentage increment in

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 Adem et al., American International Journal of Research in Science, Technology, Engineering & Mathematics, 10(4), March-May, 2015,
pp. 377-383

compressive strength of the given composite is 77.68% and 11.32% for the first and second strain rate values
respectively.
The failure mode of compression, both E-glass/Epoxy composite and E-glass/Polyester composite shows the
micro-buckling of fibers along the shear plane due to global shearing of laminate as shown in Fig. 10 (a and b).
Fig. 10 Compressive failure modes (a) E-glass/Epoxy and (b) E-glass/Polyester composites

D. Flexural Test
Fig. 11 (a) presents quasi-static strain rate effects on flexural strength for E-glass/epoxy composite as a function
of strain rate. The test results presented are based on average values of three specimens. It can be clearly seen
that the flexural strength was increasing trend with the increase of strain rate. The percentage increment for the
first two strain rate values are 20.24% and 12.21%. The effect of strain rate on flexural strength of E-
glass/Polyester composite is shown in figure 11 (b). The given graph indicates the flexural strength of E-
glass/Polyester composite was decreased with the increase of strain rate. The percentage decrement in flexural
strength of the given composite is 18.5% and 5.61% for the first and second strain rate values respectively.

Fig. 11 Flexural strength of (a) E-glass/Epoxy & (b) E-glass/Polyester composites

450
450
0.00003175 s-1 400 0.00003175 s-1
400 0.0003175 s-1
0.0003175 s-1
0.003175 s-1 350 0.003175 s-1
350
Flexural Stress [MPa]
Flexure Stress [MPa]

300 300

250 250

200 200

150 150

100 100

50 50

0 0
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0 0.01 0.02 0.03 0.04 0.05 0.06 0.07
Flexure Strain [mm/mm] Flexural Strain [mm/mm]

E. Scanning Electron Microscopy Observations

Scanning electron microscope (SEM) pictures of E-glass/epoxy composite surfaces before tensile test were
obtained with different magnification scale as shown in Fig. 12 a-d. Fiber bonding and adhesion between the
fiber and the matrix are clearly figured out from morphological studies. The interaction between matrix and
glass fibers is good as it is seen from scanning electron microscope pictures. Fig. 12 a-b shows a small pores
area. This is due to imperfect pump suction during manufacturing process. This area is a crack initiation during
the application of load on tests leads pre-mature failure. The other area on this picture shows good, which
clearly reveals strong adhesion and good interface attraction between glass fibers and matrix material. Figure 12
c-d showed a rough surface and the strongly bonded fiber-matrix interface.
Fig. 12 SEM picture at different magnification scales before test (a) 109 X (b) 143 X (c) 998 X (d) 500 X

Fig. 13 a-c shows SEM picture when the surface is observed after tensile test was conducted. Fig. 13a indicates
that some fibers are pulled out of the matrix as a result of mechanical fracturing done in tensile test. In
Figure 13 b-c, some glass fiber experience fiber pull out and delamination, which are the key features that are

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 Adem et al., American International Journal of Research in Science, Technology, Engineering & Mathematics, 10(4), March-May, 2015,
pp. 377-383

associated with the composites but very little fiber pull out was observed in the case of the thermoplastic
modified epoxy matrix and GFRP composites, which reveals the efficiency of the modified matrix to
hold the fibers. Strong interaction between thermoplastic and epoxy resin in matrix material leads to efficient
stress transfer from the matrix to reinforcing glass fibers that reduce the crack growth rate, leading to
good mechanical strength of the composites.[5]
Fig. 13 SEM pictures after tensile test (a) 500 X (b) 102 X (c) 124 X

IV. Conclusion
The tensile, compression, flexural and in-plane shear properties of plain woven E-glass/Epoxy &E-
glass/Polyester composite are presented under quasi-static strain rate and the following conclusions are
obtained. The compressive, shear and flexural properties of E-glass/Epoxy composite have an increasing trend
when the strain rate is increasing; whereas the tensile strength decreases as the strain rate increases. In case of E-
glass/Polyester composite, the tensile strength and compressive strength increases as the strain rate increases and
the in-plane shear and flexural strength show a decreasing trend as the strain rate increases. SEM observation
indicates the main problem of E-glass reinforced with epoxy and polyester is that fiber pull-out and
delamination.

V. References
[1] Giovanni Belingardi, Ermias Gebrekidan Koricho, ‘developing composite engine support sub-frame to achieve lightweight
vehicles’, 16th International Conference on Composite Structures ICCS 16, 2011 Porto.
[2] Ermias Gebrekidan Koricho, ‘implementation of composite and plastics materials for vehicle light weight’, PH.D Thesis, 2012, p
44-74.
[3] A. F. Hamed, M. M. Hamdan, B. B. Sahari and S. M. Sapuan, ‘experimental characterization of filament wound glass/epoxy and
carbon/epoxy composite materials’, ARPN Journal of Engineering and Applied Sciences, vol.3, no.4, august 2008.
[4] Barbero,E. J. 1998. ‘Introduction to Composite Materials Design’, Taylor & Francis, Philadelphia.
[5] Rafael Celeghini Santiago ,Ricardo Lessa Azevedo , Antônio F. Ávila , Marcílio Alves, George C. Jacob, J. Michael Starbuck,
John F. Fellers, Srdan Simunovic, Raymond G. Boeman ‘Mechanical characterization of glass/epoxy composite material with
nanoclays’ Received 4 November 2003; accepted 16 March 2004, DOI 10.1002/app.20901, Published online in Wiley
InterScience ([Link]).
[6] Okoli, O. I;Smith, G. F. In Proceedings of Society of Plastics Engineers Annual Technical Conference (ANTEC), Advanced
Polymer Composites Division, 1995, Vol.2, p. 2998 –3002.
[7] Keshavamurthy Y C , Dr. Nanjundaradhya N V ,Dr. Ramesh S Sharma, Dr. R S Kulkarni , ‘Investigation of Tensile Properties of
Fiber Reinforced Angle Ply laminated composites’, International Journal of Emerging Technology and Advanced Engineering
Website: [Link] (ISSN 2250-2459, Volume 2, Issue 4, April 2012), p 700-703
[8] Angelo G. Facc, Mark T. Kortschot, and, Ning Yan, ‘Predicting the Tensile Strength of Natural Fiber Reinforced
Thermoplastics’, Composites Science and Technology 67 (2007) 2454 –2466.
[9] Daniel Gay, Suong V. Hoa and Stephen W. Tsai, ‘Composite materials design and applications’, © 2003 by CRC Press LLC
[10] Donald F. Adams, Leif A. Carlsson, and R. Byron Pipes, “Experimental Characterization of Advanced Composite Materials,”
CRC Press.
[11] ASTM D3039. 1995. ‘Standard Test Method for Tensile Properties of Polymer MatrixComposite Materials’. Annual Book of
ASTM Standards, American Society for Testing and Materials, Philadelphia.14 (2): 99-109.
[12] ASTM D3518. 1994. ‘In-planeShearResponse of Polymer MatrixComposite Materials byTensile Test at ±45o Laminate’. Annual
Book of ASTM Standards, Vol. 14.01, American Society for Testing and Materials, Philadelphia. pp. 139-145.

VI. Acknowledgements
The author would like to express appreciation to Dejen Aviation Industry, unmanned air vehicle department and all composite fiber shop
staffs for supplying all the necessary materials for manufacturing of the samples. Thanks to Addis Ababa Institute of Technology
mechanical testing laboratory staff members for universal testing machine and Adama Science & Technology University, Materials
Engineering department staffs for providing all the necessary materials for SEM observations.

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