Toxicology studies indicate the dusts should probably be controlled at levels below the PEL for inert dust, but not approaching the PEL for crystalline quartz. www.zortrax.com | 2 / 13 SAFETY DATA SHEET Resin BASIC 2.2. Phenolic and amino resins are another group of PMC resins. Contact with the liquid may cause defatting of the skin and dermatitis. Since the reinforced plastics, or polymer matrix composite industry is much larger than the subject of this chapter, the term "advanced composites" is used here to define this special segment of the industry. Silicon carbide fiber A reinforcing fiber with high strength and modulus; density is equal to that of aluminum. A prepreg product is laid down and formed to the desired shape (Figure III:1-4). Glass fibers, used as reinforcement in PMC processes, are a continuous-filament form and not the glass-wool (random) type. Polar winding A type of filament winding in which the filament path passes tangent to the polar opening at one end of the chamber and tangent to the opposite side of the polar opening at the other end of the chamber. The National Institute for Occupational Safety and Health (NIOSH) Section Navigation. Materials within these categories are often called "advanced" if they combine the properties of high strength and high stiffness, low weight, corrosion resistance, and in some cases special electrical properties. As measured by load/bond area, the stress required to separate a layer of material from that to which it is bonded. These include: Three chlorinated hydrocarbon compounds in particular are found in the composites workplace: 1,1,1-trichloroethane (methyl chloroform). Precautions must be taken when using organic solvents because they can facilitate the entry of toxic materials into the skin and organ systems. Bond strength The amount of adhesion between bonded surfaces. The hazards. as a cleaning agent for removing residue from the process equipment. Should the handling of these hardeners generate dust, measures should be taken to prevent inhalation. POTENTIAL HEALTH EFFECTS Eye contact Dust/powder may irritate eye tissue. Condensation A polymerization reaction in which simple by-products (for example, water) are formed. No additional pressure is used. Thermosetting resins predominate today, while thermoplastics have only a minor role in advanced composites manufacture. Under normal conditions of storage and handling, no significant amounts of hazardous vapors should evolve from the "as sold" product. Pitch-based carbon fibers may be associated with an increased risk of skin cancer, although the evidence is weak. Quasi-isotropic Approximating isotropy by orientation of plies in several directions. Several solvents may be used in any one composite process. Unbond Area of a bonded surface in which bonding of adherends has failed to occur, or where two prepreg layers of a composite fail to adhere to each other; also denotes areas where bonding is deliberately prevented to simulate a defective bond. Many of the materials, particularly the resins, curing agents, and fibers, present a potential dermal-exposure hazard. Several layers may be required. Thermoplastic A plastic material that is capable of being repeatedly softened by application of heat and repeatedly hardened by cooling. Still another may be used for cleanup. This combination of properties makes advanced composites very attractive for aircraft and aerospace structural parts. Also called resole. Eng. Both thermoset and thermoplastic systems will be discussed in more detail in. Thus the hazard information for all products used in the process must be considered when evaluating potential exposures. Several of the solvent classes most commonly found in the PMC workplace are listed below, along with general hazard information. Fauske. Viscosity The tendency of a material to resist flow. This means that, in many cases, glove and clothing selection must be a trial and error process. PELS for these chemicals are set at levels designed to avoid any significant health risk and are achievable with proper material handling procedures, ventilation and housekeeping. It differs from filament winding (below) in several ways: there is no limit on fiber angles; compaction takes place online via heat, pressure, or both; and fibers can be added and dropped as necessary. At the same time, much of the technology is new and not presented formally in secondary or undergraduate education. One or more may be introduced as part of the resin or curing agent, while another may be a part of the manufacturing process. Some hydrophthalic anhydrides have high vapor pressures at the usual processing and curing temperatures and the vapors evolved during use of these curing agents can have an irritating effect on the skin, eyes, and respiratory tract. Polymerization A chemical reaction in which the molecules of monomers are linked together to form polymers. 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. Several advanced composite processes involve some worker contact with the resin mixture. Consolidation A processing step that compresses fiber and matrix to reduce voids and achieve a desired density. Several ketones are frequently found in PMC manufacture. Yarn Continuously twisted fibers or strands suitable for use in weaving into fabrics. Airborne fiber of this diameter does not reach the alveoli and is nonrespirable. TTY Symptoms of systemic poisoning often involve an initial, transient CNS stimulation, followed rapidly by CNS depression. Ablative A material that absorbs heat through a decomposition process called pyrolysis at or near the exposed surface. Fiber reinforcement materials are added to the resin system to provide strength to the finished part. Vapors may also cause eye irritation. Storage life The amount of time a material can be stored and remain suitable for use. In plain weave, the warp and fill fibers alternate to make both fabric faces identical; in satin weave, the pattern produces a satin appearance, with the warp tow over several fill tows and under the next one (for example, eight-harness satin would have warp tow over seven fill tows and under the eighth). However, potential for dermal exposure is frequently high. Acute exposure to high concentrations of benzene vapour can result in central nervous system depression (eg impaired thinking, blurred vision), arrhythmias as well as irritation of the skin, eyes and respiratory system. Because phenol is more soluble in the resin than in water, there is no liquefying significant health hazard MATERIAL SAFETY DATA SHEET ● Occupational Safety and Health Administration, Department of Labor, Final Rule: Occupational Exposure to 4,4'Methylenedianiline (MDA) for 29 CFR Parts 1910 and 1926. Draft angle A mandrel's taper or angle for ease of part removal. They may be biologically active and cause irritation or sensitization. Many of the solvents used in advanced composite processes are volatile and flammable. Amorphous Polymers that have no order to their molecules, thus no crystalline component. Autoclave A closed vessel that permits application of pressure and heat used for curing composites. Seven manufacturing processes are covered, along with two preliminary processes and two finishing processes. Interlaminar shear The shearing force tending to produce displacement between two laminae along the plane of their interface; usually the weakest element of a composite. Toxicity is usually related to irritation of the conjunctivae and the mucous membranes of the upper airway. Starved joint A joint that does not have the proper amount of adhesive because of insufficient spread or excessive pressure. Respiratory protection is not required in many advanced composites processes, due to the low vapor pressure of the materials involved. Fracture A rupture of the surface of a laminate because of external or internal forces, with or without complete separation. Resorcinol which can cause erythema’s and skin irritations, is water-soluble and therefore harmful to the environment and the human organism. Acetone is a popular solvent used for cleanup and may be found around the workplace in containers for this purpose. Aspect ratio The ratio of length to diameter of a fiber. In its pure state, phenol is a toxic and potentially deadly substance. Honeycomb Resin-impregnated material manufactured in, usually, hexagonal cells that serves as a core material in sandwich constructions. Related Pages. The various types of workplace controls described below may typically be found in the advanced composite workplace. Continuous-filament glass fiber is not considered fibrogenic. Honeycomb may also be metallic or polymer materials in a rigid, open-cell structure. This also is true for mixtures of solvents, as little or no testing has been done. Coefficient of thermal expansion A material's fractional change in length for a given unit change of temperature. Two of the most widely used are the aromatic amines, MDA (4,4'-methylenedianiline) and DDS (4,4'-diaminodiphenyl-sulfone). Curing agents, or hardeners, used with the epoxy resins are mostly amines, amides, or anhydrides. Reinforcement A material added to the matrix to provide the required properties; ranges from short fibers through complex textile forms. 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. 800-321-6742 (OSHA) Resin transfer molding is used when parts with two smooth surfaces are required or when a low-pressure molding process is advantageous. Co-woven fabric A reinforcement fabric woven with two different types of fibers in individual yarns; for example, thermoplastic fibers woven side by side with carbon fibers. Dusts may be generated in several ways in advanced composite processes. Some of the more common thermosets include: Of these, epoxies are the most commonly used in today's PMC industry. Impact strength A material's ability to withstand shock loading as measured by the work done in fracturing a specimen. After forming, the lay-up assembly is moved to an autoclave for cure under heat, vacuum and pressure. End-users also tend to be large, and many are in the aircraft and aerospace businesses. These compounds are formed by reacting the polyol component with an isocyanate compound, typically toluene diisocyanate (TDI); methylene diisocyanate (MDI) and hexamethylene diisocyanate (HDI) are also widely used. Phenol formaldehyde resins are an impeccable alternative for resorcinol. Ingredients of the paint or coating being removed, such as lead or chromates, may also be of concern. In June 1987, the International Agency for Research on Cancer (IARC) categorized continuous-filament glass fibers as not classifiable with respect to human carcinogenicity. Carbon fibers may be coated with a material to improve handling, known generically as sizing. The aromatic amines may permeate many of the commonly used protective gloves and thus may be particularly difficult to protect against. Cross laminated Material laminated so that some of the layers are oriented at various angles to the other layers with respect to the laminate grain. Typically they are high-viscosity liquids. Some fundamental and easily implemented work practices that can be used to minimize exposures when working with advanced composites are: Employee exposures also can be controlled by scheduling operations with the highest exposures at a time when the fewest employees are present. 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. MDA is an animal carcinogen and a suspect human carcinogen by any exposure route: ingestion, inhalation, or dermal. Although they came into existence at the very start of the age of polymers, they continued to be developed into more and more applications. Pitch A residual petroleum product used in the manufacture of certain carbon fibers. In addition to its natural complexity, phenolics machining also brings with it its fair share of hazards to watch out for, too. Often the glove selection process is one of trial and error. Like the epoxies, these compounds have a very low vapor pressure and usually do not present an airborne hazard unless in a mixture that is sprayed or cured at high temperatures. The aerospace industry, including military and commercial aircraft of all types, is the major customer for advanced composites. Modulus A measure of the ratio of load (stress) applied to the resultant deformation of a material, such as elasticity or shear. There are several types of epoxy compounds including glycidyl ethers (or diglycidyl ethers), glycidyl esters, and glycidyl amines. Structural bond A bond joining load-bearing components of an assembly. … The constituents do not dissolve or merge completely but retain their identities as they act in concert. Chemical vapor deposition (CVD) A process in which desired reinforcement material is deposited from vapor phase onto a continuous core; boron on tungsten, for example. Specific gravity The density (mass per unit volume) of a material divided by that of water at a standard temperature. The tape is applied across the surface of a mold in multiple layers by the preprogrammed robot (Figure III:1-5). Wet layup The application of resin to dry reinforcement in the mold. Handbook of Composites. Weft The yarns running perpendicular to the warp in a woven fabric; also called "woof.". These materials, along with a catalyst or curing agent and some type of fiber reinforcement (typically glass fibers) are used in the production of a wide spectrum of industrial components and consumer goods: boats, piping, auto bodies, and a variety of other parts and components. Resin starved Localized area lacking sufficient resin for wetout of the fibers. After winding, the part is cured in an oven. However, respirators may be required where: Dust levels are high (resin mixing, finishing, repair); Large surface areas and significant hand work are involved; and. Usually an inert atmosphere is provided inside the autoclave through the introduction of nitrogen or carbon dioxide. This identification has led to more use of these materials in existing facilities as well as an increase in the number of advanced composites manufacturing locations. (1-3) Symptoms of acute toxicity in humans include irregular breathing, muscle weakness and tremors, loss of 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. Legionnaire's Disease, see OSHA's Safety and Health Topics Page for updated information. The industry can be generally divided into two basic segments, industrial composites and advanced composites. Phenolic resins boards are a new substitute of wood in highly aggressive environments. Health effects typical of the group include irritation of the eyes and upper respiratory tract, dizziness, confusion, drowsiness, nausea, vomiting, and occasionally abdominal pain. Advanced composites have been identified as an important growth sector in U.S. manufacturing. Fatigue strength Maximum cyclical stress withstood for a given number of cycles before a material fails. High molecular weight is generally associated with decreased volatility. Generally, the resins are of a larger molecular size and so are less likely to permeate protective materials than the curing agents and solvents. Advanced composite systems are divided into two basic types, thermosets and thermoplastics. These and the other processes are discussed in more detail in. Dry winding A type of filament winding in which preimpregnated roving is used. The selection of reinforcement material is based on the properties desired in the finished product. Details on health hazard information and workplace controls are provided in Sections VI and VII of this chapter. Please click the button below to continue. 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