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Content

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selin özkan

on 22 May 2014

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Content
Introduction
Manufacturing Process & Application Areas
Sustainability
Economic Aspects
Companies
Introduction
Manufacturing Process & Application Areas
Composite Materials Production:
SMC & BMC

Composite materials

are composed of a mixture of two or more constituents, giving them mechanical and thermal properties which can be significantly better than those of homogeneous metals, polymers and ceramics


What is SMC & BMC?
SMC and BMC are abbreviations of respectively
Sheet Molding Compound
and
Bulk Molding Compound
.

SMC and BMC form a family of structural, fiber reinforces thermosetting resins.
Base materials of SMC and BMC are
unsaturated polyester resins, glass and mineral filler materials
, such as chalk or aluminum trihydrate.


Specific properties such as flame retardancy, surface quality and paintability can be achieved by adding specific, functional materials.
Sheet Molding Compound
Sheet Molding Compound (SMC) is a
compression molding compound
often used for larger parts where higher mechanical strength is needed.

SMC is a fiber reinforced thermoset material.

Sheet Molding Compound (SMC) is a mixture of
polymer resin, inert fillers, fiber reinforcement, catalysts, pigments and stabilizers, release agents, and thickeners and possesses strong dielectric properties.
SMC Physical Property
Bulk Moulding Compound
BMC consists of
polyester resin, glass fiber and various mineral fillers.
Using BMC in the compression moulding process we can produce high-volumes of small complex parts with optimal electrical and corrosion resistant properties. 

The fire-retardant nature of the compound makes it ideal for use in the electrical or lighting industry.
BMC Physical Property
What is composite material?
SMC/BMC is safe for the environment and can be handled in the industry in such a way that it has no effect on the human body.

SMC/BMC facilitates the generation of green energy

Heavy metals are pro-actively eliminated from the SMC/BMC industry.

SMC/BMC does not contain halogens to achieve good fire properties.

SMC/BMC has the potential to be 100% bio-based
SMC Process
Sheet Moulding Compound is an
integrated ready-to-mould
composition of glass fibre’s, resin and filler.

SMC is made by 
metering a resin paste onto a thin plastic carrier film.

The resin is typically
thermoset Polyester
but alternatives are available such as vinyl, Phenolic and Acrylic modified depending on the ultimate properties required. 

 The compound is made by
chopping continuous fibers onto the resin paste as it is conveyed on the film
.
This glass, resin mix is further covered by another layer of resin on a second carrier film.

 Compaction rollers knead the fibers into the resin
for uniform fiber distribution and wetting.

The compound sandwiched between the carrier films is gathered into rolls and stored until it matures.
BCM Process
The basic raw materials
resins, additives, catalysts, mould

release agents and fillers
are mixed under high shear to produce a viscous paste similar to SMC process.

 To this paste
glass fibers
are added and the kneading process continued for a short period. The fibrous
dough - like
compound is then packed into Styrene proof bags until moulding.
Gökçe Şahin
Selin Özkan
Meltem Polat
Gökçen Çevik

SMC and BMC product are used in a very broad range of applications, such as:
Automotive:
cars, trucks and other commercial and agricultural vehicles

Mass transport:
trains, trams, light railways and monorail

Sanitary :
bathroom suites and hygienic surfaces
Building & construction:
civil engineering and household fixtures

Domestic appliances:
coffee machines, toasters, irons, etc.

Electrical & electronics:
housing, fuses, switchgear, etc.

Sustainability
Continuous filament glass fibers are not respirable and not classified as a suspected carcinogen
SMC/BMC parts have a long lifetime, without the need of maintenance
SMC and BMC electrical cabinets have a long track record as durable application. Outdoor exposed cabinets are already in service for more than 30 years, without the need for maintenance.
In comparison with traditional materials, such as steel, aluminum and concrete,
SMC and BMC products have a low environmental impact
, which is given by a total set of arguments:

Low energy content in production
Low emissions in production
Low weight
Low maintenance
Long lifetime
Recyclable

These arguments make products made in SMC and BMC an excellent construction material to contribute to a better world.

Companies
Companies In the World
IDI Composites International
Retterbush Fiberglass Corporation
Chattahoochee Specialty Composites,Inc.
Molding Technologies Inc.
Companies In Turkey
Tongün Grup
Alpin Kimya Sanayi ve Ticaret A.Ş
Literatür Kimya
Gamafrp Kompozit Teknolojileri Sanayi
Economic Aspect

The European Alliance for SMC/BMC released the European market figures for 2010 & 2011 related to products and market
applications.
Based on the 2009 – 2010 comparison, the production volume of SMC/ BMC in Europe increased to around 10%
.

Concerning 2011 figures, the market data is foreseeing an estimated additional growth of around 7% which brings the total volume to around 240.000 tons
The market data in figure below shows the 2008 – 2011 compared market data for BMC and SMC.

Concerning market applications of SMC/ BMC , the 2010 & 2011 data showed a stable volume.
Electrical & electronics
applications continue to lead SMC/BMC
market segments

(42%), followed by transportation (40%), construction & household (12%) and others (6%)
.
Compared to 2010, SMC/BMC applications in transportation increased slightly.

China has been left relatively untouched by the recession in the composites sector and is continuing to draw on this growth.
In 2010
, its production represented
28% of global production
, the largest share.

In the same year, the USA represented in
excess of 22% of global production
, and Europe represented
20%
. The rest of the world produces
29%
of composites.

Excellent mechanical properties

even at very high and low temperatures


Design freedom


Low thermal expansion coefficient comparable to steel


Low weight
Low weight means energy saving over the lifetime of a part;
greater fuel efficiency and reduced CO2 emissions
through the life of vehicle.


High temperature paintability

• Chemical resistance
Resistant to
acidic and alkaline chemical environments, water, moisture.

Excellent dimensional accuracy and stability

• Low system cost through integration of parts and functions


Flame retertand and low smoke emissions, halogen free formulations
Fire safety in mass transit vehicles and public buildings.

• Superior sound demping compared to aluminium and steel

• Customzation
SMC/BMC are
highly versatile materials
that can be custom formulated and moulded to meet exact performance.
Advantages of SMC & BMC
Thank you!

The environmental benefits of metals are only based on the possibility to recycle metals. SMC/BMC has much more environmental arguments, such as light weight, low energy consumption, long lifetime AND recyclability.
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