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Lightweight Polymer
Composite Structures
 Lightweight Polymer
Composite Structures
Design and Manufacturing Techniques

Sanjay Mavinkere Rangappa,

Jyotishkumar Parameswaranpillai,
Suchart Siengchin, and Lothar Kroll
First edition published 2020
by CRC Press
6000 Broken Sound Parkway NW, Suite 300, Boca Raton, FL 33487-2742

and by CRC Press

2 Park Square, Milton Park, Abingdon, Oxon, OX14 4RN

© 2021 Taylor & Francis Group, LLC

CRC Press is an imprint of Taylor & Francis Group, LLC

Reasonable efforts have been made to publish reliable data and information, but the author and publisher can-
not assume responsibility for the validity of all materials or the consequences of their use. The authors and
publishers have attempted to trace the copyright holders of all material reproduced in this publication and
apologize to copyright holders if permission to publish in this form has not been obtained. If any copyright
material has not been acknowledged please write and let us know so we may rectify in any future reprint.
Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced, transmit-
ted, or utilized in any form by any electronic, mechanical, or other means, now known or hereafter invented,
including photocopying, microfilming, and recording, or in any information storage or retrieval system, with-
out written permission from the publishers.

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contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood Drive, Danvers, MA 01923, 978-750-8400.
For works that are not available on CCC please contact mpkbookspermissions​@tandf​.co​​.uk

Trademark notice: Product or corporate names may be trademarks or registered trademarks, and are used only
for identification and explanation without intent to infringe.

ISBN: 978-0-367-19920-3 (hbk)

ISBN: 978-0-429-24408-7 (ebk)

Typeset in Times
by Deanta Global Publishing Services, Chennai, India
Contents
Preface......................................................................................................................vii
Editor Biographies.....................................................................................................ix
Contributors............................................................................................................ xiii

Chapter 1 Lightweight Graphene Composite Materials........................................1

Akarsh Verma, Naman Jain, Avinash Parashar,
Vinay K. Singh, M. R. Sanjay, and Suchart Siengchin

Chapter 2 Conventional Processing of Polymer Matrix Composites.................. 21

M.K. Singh, N. Verma, and S. Zafar

Chapter 3 Biodegradable and Biocompatible Polymer Composite:

Biomedical Applications and Bioimplants.......................................... 67
Naga Srilatha Cheekuramelli, Dattatraya Late, S. Kiran, and
Baijayantimala Garnaik

Chapter 4 Lightweight Polymer Composites from Wood Flour, Metals,

Alloys, Metallic Fibers, Ceramics....................................................... 89
E. Teke, M. Sütçü, V. Acar, and M. Ö. Seydibeyoğlu

Chapter 5 Lightweight Composite Materials in Transport Structures............... 103

M. Özgür Seydibeyoğlu, Alperen Doğru, M. Batıkan Kandemir,
and Özay Aksoy

Chapter 6 Hybrid Thermoplastic and Thermosetting Composites.................... 131

N. R. Singha, P. K. Chattopadhyay, M. Karmakar, and H. Mondal

Chapter 7 Design and Modeling of Lightweight Polymer Composite

Structures.......................................................................................... 193
Akarsh Verma, Naman Jain, Avinash Parashar,
Vinay K. Singh, M. R. Sanjay, and Suchart Siengchin

Chapter 8 Smart Lightweight Polymer Composites........................................... 225

Nayan Ranjan Singha, Mousumi Deb, Manas Mahapatra,
Madhushree Mitra, and Pijush Kanti Chattopadhyay

v
vi Contents

Chapter 9 Carbon Fiber Reinforced Thermoplastics and Thermosetting

Composites........................................................................................ 267
Deepak Verma

Chapter 10 Glass Fiber Thermoset and Thermoplastic Composites................... 289

T P Sathishkumar and Gobinath Velu Kaliyannan

Chapter 11 Inorganic Nanofillers-Based Thermoplastic and Thermosetting

Composites........................................................................................309
M. Chandrasekar, T. Senthil Muthu Kumar, K. Senthilkumar,
N. Mohd Nurazzi, M.R. Sanjay, N. Rajini, and Suchart Siengchin

Chapter 12 Applications of Thermoplastic and Thermosetting Polymer

Composites........................................................................................ 331
Sanjay Remanan, Sabyasachi Ghosh,
Tushar Kanti Das, and Narayan Chandra Das

Chapter 13 Life Cycle Assessment of Thermoplastic and Thermosetting

Composites........................................................................................ 359
Alexander Kaluza, Johanna Sophie Hagen, Antal Dér,
Felipe Cerdas, and Christoph Herrmann

Index....................................................................................................................... 387
Preface
Polymers are lightweight materials that are used for many advanced applications
such as automobile, construction and building, aerospace, toys, household appli-
ances, etc. However, during its operation in many applications, polymer materials
are exposed to harsh environments, high load, friction, wear and tear, etc. Scientists
have established that the incorporation of fillers has significantly improved the ther-
momechanical, electrical, and other physical properties of polymer composites.
Thus, to withstand the external forces during use, micro and nanofillers including
both natural and synthetic fibers such as carbon nanotubes, carbon black, graphene,
nanoclay, nanosilica, plant fibers, glass fibers, carbon fibers, carbon mats, plant fiber
mats, etc., were added to the thermoplastics or thermosetting plastics. Moreover,
many fillers aid additional functionality to the polymers. For example, when carbon-
based fillers such as carbon nanotubes, carbon nanofibers, graphene, etc., are used
with polymers, it imparts conductivity to the polymers. Similarly, magnetic particles
are incorporated in polymers to aid shape memory properties. Recently, polymer
composites have been the preferred option for making components for automobile,
aerospace, and marine applications due to their lightweightedness, that enhances the
energy and fuel efficiency, thus making the entire industry more environmentally
friendly.
Significant progress has been made in the area of lightweight polymer composite
structures in the last decade. This has led to a surge in the number of papers, patents,
and reviews on the subject. Therefore, we believe it is important to edit a book on
Lightweight Polymer Composite Structures: Design and Manufacturing Techniques.
Eminent scholars have contributed the chapters for the book. We hope that this book
will be very informative for the scientist, academic staff, faculty members, research-
ers, and students working in the area of lightweight polymer composite structures.
The book consists of 13 chapters that shed light on lightweight polymer composite
structures. Chapter 1 focuses on the synthesis of graphene, its properties, and high-
lights the properties of graphene-based thermoplastic and thermosetting composites.
The authors emphasized the importance of dispersion of graphene platelets in the
polymer matrix for the enhancement of the properties. Chapter 2 discusses various
processing techniques that are commonly used for the manufacturing of polymer
composites. Chapter 3 describes the necessity of biodegradable and biocompatible
polymer composites for biomedical and packaging applications. Chapter 4 reviews
the recent developments in polymer composites including ceramics, woody materi-
als, and metal particles. Chapter 5 focuses on lightweight composites for aerospace,
marine, and automobile applications. Different processing methods such as hand
lay-up, spray-up, vacuum bagging, vacuum infusion, filament winding, resin transfer
molding, prepreg, etc., used for the manufacturing of polymer components are high-
lighted. Chapter 6 gives an overview of using more than one reinforcing filler in the
polymer matrix to introduce new properties. Chapter 7 highlights the importance of
designing and modeling of polymers for its effective utilization in real-time applica-
tions. Chapter 8 gives an overview of the recent developments in smart composites.

vii
viii Preface

The efficiency and usability of traditional polymer composites can be improved by

introducing additional functionalities. Chapters 9 and 10 discuss the use of carbon
and glass fiber in thermoset and thermoplastic composites, respectively. Chapter 11
reviews the influence of nanofillers on the thermomechanical, electrical, and physical
properties of thermoset and thermoplastic composites. Chapter 12 gives an overview
of the broad spectrum of applications of thermoplastic and thermosetting polymer
composites. The last chapter, Chapter 13, highlights the importance of life cycle
analysis on the assessment of the environmental impact of polymer composites.
The editors are thankful to the authors for their contributions and the Taylor &
Francis editorial team for their support and guidance.

Editors
Dr. Sanjay Mavinkere Rangappa (Thailand)
Dr. Jyotishkumar Parameswaranpillai (Thailand)
Prof. Dr.-Ing. habil. Suchart Siengchin (Thailand)
Univ.-Prof. Dr.-Ing. habil. Prof. h. c. Dr. h. c. Prof. Lothar Kroll (Germany)
Editor Biographies
Dr. Sanjay Mavinkere Rangappa, received a B.E.
(Mechanical Engineering) from Visvesvaraya Technological
University, Belagavi, India in 2010, M. Tech (Computational
Analysis in Mechanical Sciences) from VTU Extension
Center, GEC, Hassan, in 2013, Ph.D. (Faculty of Mechanical
Engineering Science) from Visvesvaraya Technological
University, Belagavi, India in 2017, and Post Doctorate from
King Mongkut's University of Technology North Bangkok,
Thailand, in 2019. He is a Life Member of Indian Society
for Technical Education (ISTE) and an Associate Member of Institute of Engineers
(India). He is a reviewer for more than 50 international journals and international
conferences (for Elsevier, Springer, Sage, Taylor & Francis, Wiley). In addition,
he has published more than 85 articles in high-quality international peer-reviewed
journals, 20+ book chapters, one book, 15 books as an editor, and also presented
research papers at national/international conferences. His current research areas
include natural fiber composites, polymer composites, and advanced material tech-
nology. He is a recipient of DAAD Academic exchange-Project-related Personnel
Exchange Program (PPP) between Thailand and Germany to Institute of Composite
Materials, University of Kaiserslautern, Germany. He has received a Top Peer
Reviewer 2019 award, Global Peer Review Awards, from Web of Science Group
powered by Publons.
Dr. Jyotishkumar Parameswaranpillai is currently work-
ing as a research professor at Center of Innovation in Design
and Engineering for Manufacturing, King Mongkut’s
University of Technology North Bangkok. He received his
Ph.D. in Polymer Science and Technology (Chemistry) from
Mahatma Gandhi University. He has research experience in
various international laboratories such as Leibniz Institute
of Polymer Research Dresden (IPF) Germany, Catholic
University of Leuven, Belgium, and University of Potsdam,
Germany. He has published more than 100 papers in high-
quality international peer-reviewed journals on polymer nanocomposites, polymer
blends and alloys, and biopolymer, and has edited five books. He received numerous
awards and recognitions including the prestigious Kerala State Award for the Best
Young Scientist 2016, INSPIRE Faculty Award 2011, and the Best Researcher Award
2019 from King Mongkut’s University of Technology North Bangkok.

ix
x Editor Biographies

Prof. Dr.-Ing. habil. Suchart Siengchin is President

of King Mongkut's University of Technology North
Bangkok (KMUTNB), Thailand. He received his Dipl.-
Ing. in Mechanical Engineering from University of Applied
Sciences Giessen/Friedberg, Hessen, Germany in 1999,
M.Sc. in Polymer Technology from University of Applied
Sciences Aalen, Baden-Wuerttemberg, Germany in 2002,
M.Sc. in Material Science at the Erlangen-Nürnberg
University, Bayern, Germany in 2004, Doctor of Philosophy
in Engineering (Dr.-Ing.) from Institute for Composite Materials, University of
Kaiserslautern, Rheinland-Pfalz, Germany in 2008, and Postdoctoral Research from
Kaiserslautern University and School of Materials Engineering, Purdue University,
USA. In 2016, he received the habilitation at the Chemnitz University in Sachen,
Germany. He worked as a lecturer for the Production and Material Engineering
Department at The Sirindhorn International Thai–German Graduate School of
Engineering (TGGS), KMUTNB. He has been full Professor at KMUTNB and
became the President of KMUTNB. He won the Outstanding Researcher Award in
2010, 2012, and 2013 at KMUTNB. His research interests are in polymer processing
and composite material. He is Editor-in-Chief of KMUTNB International Journal
of Applied Science and Technology and the author of more than 150 peer-reviewed
journal articles. He has participated with presentations in more than 39 international
and national conferences on Materials Science and Engineering topics.
Prof. Lothar Kroll received a Diploma in Mechanical
Engineering in 1987 and a Doctorate in Engineering
(Dr.-Ing.) in 1992 from Institute for Technical Mechanics,
Clausthal University of Technology, Germany as well as
the a habilitation in the field of Lightweight Construction
and Material Mechanics in 2005 from Dresden University
of Technology, Germany. Since 2006, Prof. Kroll is Full
Professor of Lightweight Structures and Polymer Technology
at the Institute of Lightweight Structures at Chemnitz
University of Technology, Germany. Starting with ten aca-
demic staff, he has actively established one of the largest professorships in Germany
with currently three endowed professorships, nine research areas, and more than
200 employees. Prof. Kroll won the Medal of Honor of Chemnitz University of
Technology in 2011, the Medal of Honor of Opole University of Technology, Poland,
in 2014, and the Outstanding International Academic Alliance Award at KMUTNB
in 2015. In 2017, he was awarded with the Honorary Doctorate, Doctor of Philosophy
(Ph.D.) in Production Engineering at KMUTNB. In 2018, he was made Professor
of Technical Science by the President of the Republic of Poland. Prof. Kroll is
Editor-in-Chief of Technologies for Lightweight Structures (open access journal),
Deputy Editor-in-Chief of Journal of Achievements in Materials and Manufacturing
Engineering (JAMME), Poland, on the Editorial Board of Composites Theory and
Practice (research journal of the Polish Society of Composite Materials) as well as of
Applied Science and Technology (international journal of KMUTNB). Furthermore,
Editor Biographies xi

he is on the Editorial Advisory Board of MECHANIK (Miesiecznik Naukowo-

Techniczny, Polska) and on the Editorial Key Reviewers Committee of Archives of
Materials Science and Engineering (AMSE), Poland. He is author of more than 150
peer-reviewed journal articles, in particular on the topics of manufacturing technolo-
gies for fiber- and fabric-reinforced lightweight structures, calculation of lightweight
structures under mechanical, thermal, and medial load, construction and manufac-
turing of active composites with integrated electronics, as well as merging of mate-
rial-specific manufacturing processes to technologies suitable for mass-­production
of lightweight structures.
Contributors
V. Acar Narayan Chandra Das
Atatürk University Rubber Technology Center
Erzurum, Turkey Indian Institute of Technology
Kharagpur, India
Özay Aksoy
İzmir Katip Çelebi University Tushar Kanti Das
İzmir, Turkey Rubber Technology Center
Indian Institute of Technology
Felipe Cerdas Kharagpur, India
Chair of Sustainable Manufacturing &
Life Cycle Engineering Mousumi Deb
Institute of Machine Tools & Advanced Polymer Laboratory
Production Technology (IWF) Department of Polymer Science and
Technische Universität Braunschweig Technology
Braunschweig, Germany Government College of Engineering
and and Leather Technology
Open Hybrid Lab Factory e.V. (Post-Graduate)
Wolfsburg, Germany Maulana Abul Kalam Azad University
of Technology
M. Chandrasekar West Bengal, India
School of Aeronautical Sciences
Hindustan Institute of Technology and Antal Dér
Science Chair of Sustainable Manufacturing &
Tamil Nadu, India Life Cycle Engineering
Institute of Machine Tools &
P. K. Chattopadhyay Production Technology (IWF)
Department of Leather Technology Technische Universität Braunschweig
Government College of Engineering and Braunschweig, Germany
Leather Technology (Post-Graduate) and
Maulana Abul Kalam Azad University Open Hybrid LabFactory e.V.
of Technology Wolfsburg, Germany
West Bengal, India
Alperen Doğru
Naga Srilatha Cheekuramelli Ege University, İzmir Katip Çelebi
Polymer Science and Engineering University
Division İzmir, Turkey
CSIR-National Chemical Laboratory
Pune, India
and
Academy of Scientific and Innovative
Research (AcSIR)
Ghaziabad, India

xiii
xiv Contributors

Baijayantimala Garnaik Alexander Kaluza

Polymer Science and Engineering Chair of Sustainable Manufacturing &
Division Life Cycle Engineering
CSIR-National Chemical Laboratory Institute of Machine Tools &
Pune, India Production Technology (IWF)
and Technische Universität Braunschweig
Academy of Scientific and Innovative Braunschweig, Germany
Research (AcSIR) and
Ghaziabad, India Open Hybrid LabFactory e.V.
Wolfsburg, Germany
Sabyasachi Ghosh
Rubber Technology Center, Indian M. Batıkan Kandemir
Institute of Technology İzmir Katip Çelebi University
Kharagpur, India İzmir, Turkey

Johanna Sophie Hagen M. Karmakar

Chair of Sustainable Manufacturing & Advanced Polymer Laboratory
Life Cycle Engineering Department of Polymer Science and
Institute of Machine Tools & Technology
Production Technology (IWF) Government College of Engineering
Technische Universität Braunschweig and Leather Technology
Braunschweig, Germany (Post-Graduate)
and Maulana Abul Kalam Azad University
Open Hybrid LabFactory e.V. of Technology
Wolfsburg, Germany West Bengal, India

Christoph Herrmann S. Kiran

Chair of Sustainable Manufacturing & Polymer Science and Engineering
Life Cycle Engineering Division
Institute of Machine Tools & CSIR-National Chemical Laboratory
Production Technology (IWF) Pune, India
Technische Universität Braunschweig and
Braunschweig, Germany Academy of Scientific and Innovative
and Research (AcSIR)
Open Hybrid LabFactory e.V. Ghaziabad, India
Wolfsburg, Germany
T. Senthil Muthu Kumar
Naman Jain Center for Composite Materials
Meerut Institute of Engineering & Department of Mechanical Engineering
Technology Kalasalingam Academy of Research
Meerut, India and Education
Tamil Nadu, India
Gobinath Velu Kaliyannan
Department of Mechanical Engineering
Kongu Engineering College
Tamil Nadu, India
Contributors xv

Dattatraya Late Avinash Parashar

Physical and Materials Chemistry Indian Institute of Technology
Division Roorkee, India
CSIR-National Chemical Laboratory
Maharashtra, India N. Rajini
and Center for Composite Materials
Academy of Scientific and Innovative Department of Mechanical Engineering
Research (AcSIR) Kalasalingam Academy of Research
Ghaziabad, India and Education
Tamil Nadu, India
Manas Mahapatra
Advanced Polymer Laboratory Sanjay Remanan
Department of Polymer Science and Rubber Technology Center
Technology Indian Institute of Technology
Government College of Engineering Kharagpur, India
and Leather Technology
(Post-Graduate) M. R. Sanjay
Maulana Abul Kalam Azad University Natural Composites Research
of Technology Group Lab
West Bengal, India Academic Enhancement Department
King Mongkut’s University of
Madhushree Mitra Technology North Bangkok
Department of Leather Technology, Bangkok, Thailand
Government College of Engineering
and Leather Technology T. P. Sathishkumar
(Post-Graduate) Department of Mechanical Engineering
Maulana Abul Kalam Azad University Kongu Engineering College
of Technology Tamil Nadu, India
West Bengal, India
K. Senthilkumar
H. Mondal Center for Composite Materials
Advanced Polymer Laboratory Department of Mechanical Engineering
Department of Polymer Science and Kalasalingam Academy of Research
Technology and Education
Government College of Engineering Tamil Nadu, India
and Leather Technology
(Post-Graduate) M. Ö. Seydibeyoğlu
Maulana Abul Kalam Azad University İzmir Katip Çelebi University
of Technology İzmir, Turkey
West Bengal, India

N. Mohd Nurazzi
Department of Aerospace Engineering
Faculty of Engineering
Universiti Putra Malaysia
Selangor, Malaysia
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