FRP vs Fiberglass

FRP vs Fiberglass

FRP vs. Fiberglass

“Fiberglass” and “Fiber-reinforced polymer (FRP)” are used interchangeably by many professionals. With two referring to distinct products, both differ technically. Below, we highlight the what fiberglass and FRP are and how they differ. 

What Is FRP?

Fibre-reinforced plastic (FRP; also called fiber-reinforced polymer, or fiber-reinforced plastic) is a composite material made of a polymer matrix reinforced with fibres. The fibres are usually glass (in fibreglass), carbon (in carbon fiber reinforced polymer), aramid, or basalt. Rarely, other fibres such as paper, wood, or asbestos have been used. The polymer is usually an epoxy, vinyl ester, or polyester thermosetting plastic, though phenol formaldehyde resins are still in use.

FRPs are commonly used in the aerospace, automotive, marine, and construction industries.

A polymer is generally manufactured by step-growth polymerization or addition polymerization. When combined with various agents to enhance or in any way alter the material properties of polymers, the result is referred to as a plastic. Composite plastics refers to those types of plastics that result from bonding two or more homogeneous materials with different material properties to derive a final product with certain desired material and mechanical properties. Fibre-reinforced plastics are a category of composite plastics that specifically use fibre materials to mechanically enhance the strength and elasticity of plastics.

The original plastic material without fibre reinforcement is known as the matrix or binding agent. The matrix is a tough but relatively weak plastic that is reinforced by stronger stiffer reinforcing filaments or fibres. The extent that strength and elasticity are enhanced in a fibre-reinforced plastic depends on the mechanical properties of both the fibre and matrix, their volume relative to one another, and the fibre length and orientation within the matrix. Reinforcement of the matrix occurs by definition when the FRP material exhibits increased strength or elasticity relative to the strength and elasticity of the matrix alone

Fiberglass is the reinforcement of choice for most FRP products due to it having the best combination of properties and cost. Some companies and countries refer to glass fiber-reinforced polymers (GFRP) to provide the distinction with carbon reinforcements (CFRP.).

What Is Fiberglass?

Fiberglass really is made of glass similar to that in windows or kitchen drinking glasses. To manufacture fiberglass, glass is heated until molten, then forced through superfine holes. This creates glass filaments that are extremely thin—so thin, in fact, that they’re best measured in microns.

These flexible filament threads can be used in several applications: They can be woven into larger swatches of material or left in a somewhat less structured form used for the more familiar puffy texture used for insulation or soundproofing. The final application is dependent on the length of the extruded strands (longer or shorter) and the quality of the fiberglass. For some applications, it’s important that the glass fibers have fewer impurities, however, this involves additional steps in the manufacturing process.

What’s the Difference Between Fiberglass and FRP?

We can conclude that fiberglass and FRP can be used interchangeably in most, but not all cases.  When discussing a composite material, fiberglass means a glass fiber-reinforced polymer (FRP or GFRP.)  A fiberglass composite that does not use polymer as the base material cannot be called an FRP composite.  Similarly, an FRP composite that does not use glass fibers as the reinforcement material or polymer as the base material cannot be called a GFRP composite.

Glass Fiber Reinforced Polymer / Plastics

Why is FRP (or CFRP/GFRP) used in Engineering?

 

FRP material is a versatile material with high performance characteristics. It possesses valuable engineering properties, like high strength/stiffness combined with a low density. Additionally the durability, like for instance corrosion and chemical resistance, is another characteristic that favors the application of FRT in engineering challenges.

FRP is also called CFRP when the reinforcement is carbon fiber material and GFRP when glass fibers are used.

The ‘P’ in ‘FRP’ stands for Polymer or Plastic. Alformet uses only Thermoplastic material reinforced with fibers. Thermoplastic material has the advantage of being 100% recyclable and contributes to the transition to a circular economy.

 

What is the difference between Fiber Reinforced Polymer or Plastic?

The word plastic is the common name for synthetic polymer, so there is no difference if you refer to synthetic material.  There are three types of polymers: thermoset, thermoplastic and elastomer.

Thermoset is obtained by irreversibly hardening ("curing") a soft solid or viscous liquid prepolymer (resin)

Thermoplastic, or thermosoftening plastic, is a plastic polymer material that becomes pliable or moldable at a certain elevated temperature and solidifies upon cooling.

An elastomer is a polymer with viscoelasticity (i.e., both viscosity and elasticity) and with weak intermolecular forces, generally low Young's modulus and high failure strain compared with other materials.

Fiber Reinforced Polymer/Plastic is a polymer/plastic with reinforcement from fibers. This type of material is an engineering material and substitutes metal in many applications, due to the favorable characteristics.

Alformet processes only thermoplastic material with fiber reinforcement. These are commonly called Fiber Reinforced Thermoplastics (FRTP) or Thermoplastic Composites and are 100% recyclable.

What is the difference between Fiber Reinforced Thermoplastics and Thermoplastic Composites?

 

Both terms refer normally to the same: Fiber Reinforced Thermoplastics is more often used as it specifically indicates that fibers are used to reinforce the thermoplastics. Examples are PP-GF (polypropylene with glass fibers) or PEEK-CF (polyetheretherketone with carbon fibers).

Thermoplastic Composite literally means that the composite (combination of two materials) consists of thermoplastic and another (reinforcing) element. Any other element that improves the characteristics can therefore be used (of which fibers is one option). For instance a sandwich panel of aluminium sheets with thermoplastic material in between is also called a (thermoplastic) composite.

Alformet processes only fiber reinforced thermoplastics with its laser winding technology. Thermoplastics are 100% recyclable.

 

What is CFRP and CFR-TP?

 

CFRP stands for Carbon Fiber Reinforced Polymer/Plastic and reflects a group of plastics that are reinforced with carbon fibers to provide it with high strength and stiffness, while reducing weight compared to most other materials like metals. The group of plastics which can be reinforced with carbon fibers, can be split in two main groups: thermoset and thermoplastics.

CFR-TP stands for Continuous Fiber Reinforced Thermoplastics. Thermoplastics reinforced with continuous fibers have other characteristics compared to continuous fiber reinforced thermosets.  Thermoplastics are recyclable and fit in the circular economy model.

 

What is GFRP?

 

GFRP stands for Glass Fiber Reinforced Polymer/Plastic and reflects a group of plastics that are reinforced with glass fibers to provide it with high strength and (moderate) stiffness, while reducing weight compared to most other materials like metals. The group of plastics which can be reinforced with glass fibers, can be split in two main groups: thermoset and thermoplastics.

Thermoplastic GFRP is a subgroup within the GFRP material group. Thermoplastics reinforced with glass fibers have other characteristics compared to glass fiber reinforced thermosets.  Thermoplastics are recyclable and fit in the circular economy model.

 

What are Continuous Fiber Reinforced (CFR) Thermoplastics?

 

The continuous fiber reinforced thermoplastics contain fibers that are endless or continuous. These continuous fibers offer optimal strength and stiffness as they support the full structure in contradiction to the short or long fibers, which can only bear partial loads. The highest mechanical properties of a structure can be obtained by applying continuous fibers.

 

Beetle Plastics

What are Fiber Reinforced Polymers?

Fiber Reinforced Polymers (FRP) have been defined using many terms.  Around the world FRP also goes by other names depending on market and geographic location; Fiber Reinforced Composites (FRC), Glass Reinforced Plastics (GRP), and Polymer Matrix Composites (PMC) are examples.

To keep things simple, here is a clear, concise definition.  Fiber Reinforced Polymer composites are defined as a polymer (plastic) matrix, either thermoset or thermoplastic, that is reinforced (combined) with a fiber or other reinforcing material with a sufficient aspect ratio (length to thickness) to provide a discernable reinforcing function in one or more directions.

Four Main Ingredients of Fiber Reinforced Polymers

Resins

Reinforcements- Fibers and Forms

Fillers

Additives and Modifiers

Capacity Capabilities Solutions

Through the proper selection of reinforcement, resin, and manufacturing process, a composite is design-engineered to exacting specifications for cost-effectiveness and performance.  At Beetle we can take your design idea and turn it into a constructible solution.

We will exceed your expectations for project timing, design and integration, and finished product quality. We offer unrivaled industry know-how and precision capabilities to help assist you with your specific challenges.

Anisotropic vs. Isotropic

There are significant differences with respect to mechanical properties when comparing FRP with metals such as steel or aluminum.  FRP are anisotropic, that is, they posses mechanical properties only in the direction of the applied load.  In other words, their best mechanical properties are in the direction of the fiber placement.  Conversely, steel and aluminum are isotropic, giving them uniform properties in all directions, independent of the applied load.

Dimensional Stability

According to an Introduction to Dimensional Stability of Composite Materials, 2004, by Ernest G. Wolff, dimensional stability is a relative term; it does not really exist except within the artificial confines of a tolerance, specification or measurement accuracy.  This is because, at an atomic level all materials respond to internal or external stresses, to temperature, to the absorption of solutes, to radiation, gravity, and most likely any conceivable phenomenon.

That being said, composites have exceptional inherent dimensional stability potential due to their unique formulations.  Because composites are customizable, they can be designed to maximize the benefits of structural properties. They are often selected by engineers when applications requiring stringent dimensional stability under a variety of extreme conditions exist.

Because composites have good dimensional stability or structure, and other properties such as light weight, strength, toughness, damage tolerance, fatigue and fracture resistance, notch sensitivity, and general durability, they are desirable for many applications in a variety of industries.

For example, composites are used in structural applications for aircraft, spacecraft, automobiles, railcars, automobiles, sports equipment, missiles, infrastructure, chemical processing, and energy generation devices, such as cooling towers and wind turbines.

Composition

There are four main ingredients that FRP are comprised of: resins, reinforcements, fillers and additives/modifiers.  Each ingredient is equally important and all ingredients play an important role in determining the properties of the finished FRP products.  To simplify, think of the resin (polymer) as the glue or the binding agent.  The mechanical strength is provided by the reinforcements.

Resins

The primary functions of the resin are to transfer stress between the reinforcing fibers, act as a glue to hold the fibers together, and protect the fibers from mechanical and environmental damage. Resins are divided into two major groups known as thermoset and thermoplastic. Thermoplastic resins become soft when heated, and may be shaped or molded while in a heated semi-fluid state and become rigid when cooled. Thermoset resins, on the other hand, are usually liquids or low melting point solids in their initial form.

Reinforcements- Fibers and Forms

There are four main types of fibers commonly used in the FRP industry; glass, carbon, natural and arimid. Each has their own advantages and applications. Similarly, reinforcements are available in forms to serve a wide range of processes and end-product requirements. Common materials used as reinforcement include woven roving, milled fiber, chopped strands, continuous, chopped or thermoformable mat. Reinforcement materials can be designed with unique fiber architectures and be preformed (shaped) depending on the product requirements and manufacturing process.

Fillers

Fillers are used as process or performance aids to impart special properties to the end product. Some examples of inorganic fillers include calcium carbonate, hydrous aluminum silicate, alumina trihydrate and calcium sulfate.  In some circumstances, fillers and additives play a critical role in lowering the cost of compounds by diluting expensive resins and reducing the amount reinforcements.  Furthermore, fillers and additives improve compound rheology, fiber loading uniformity, enhance mechanical and chemical performance and reduce shrinkage.

Additives and Modifiers

Additives and modifiers perform critical functions despite their relative low quantity by weight when compared to the other ingredients; resins, reinforcements and fillers.  Some additives used in thermoset and thermoplastic composites include: low shrink/low profile (when smooth surfaces are required), fire resistance, air release, emission control, viscosity control, and electrical conductivity, are among others.

An important note is that FRP products can be custom made for their intended use.  Understanding the intended function and services of the FRP, will aid the design and manufacturing processes to allow for an optimal finished product (i.e. corrosion resistance).  Modifiers can include catalyst, promoters, inhibitors, colorants, release agents and thixotropic agents (fumed silica and certain clays).

Key Benefits of Using FRP

There are a multitude of key benefits realized when utilizing FRP in your project design.

For starters they are light-weight, extremely strong, low maintenance, durable, weather resistant, corrosion and abrasion resistant, and in many cases cost-effective.  FRP are the ultimate materials solution.

Light Weight

Directional Strength

Weather Resistant

Radar Transparency

High Dielectric Strength

Long-Term Durability

Noise Reduction

Custom Surface Finish

Does Not Require Cathodic Protection

High Strength to Weight Ratio

Corrosion and Abrasion Resistant

Non-Magnetic

High Impact Strength

Low Maintenance

Part Consolidation

UV Resistant

Dimensional Stability

Low thermal conductivity

Low coefficient of thermal expansion