Fiberglass Science and Technology: Chemistry, Characterization, Processing, Modeling, Application, and Sustainability [1st ed. 2021] 303072199X, 9783030721992

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Hong Li  Editor

Fiberglass Science and Technology Chemistry, Characterization, Processing, Modeling, Application, and Sustainability

Fiberglass Science and Technology

Hong Li Editor

Fiberglass Science and Technology Chemistry, Characterization, Processing, Modeling, Application, and Sustainability

Editor Hong Li Nippon Electric Glass Shelby, NC, USA

ISBN 978-3-030-72199-2 ISBN 978-3-030-72200-5 https://doi.org/10.1007/978-3-030-72200-5

(eBook)

© Springer Nature Switzerland AG 2021 This work is subject to copyright. All rights are reserved by the Publisher, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission or information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilar methodology now known or hereafter developed. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. The publisher, the authors, and the editors are safe to assume that the advice and information in this book are believed to be true and accurate at the date of publication. Neither the publisher nor the authors or the editors give a warranty, expressed or implied, with respect to the material contained herein or for any errors or omissions that may have been made. The publisher remains neutral with regard to jurisdictional claims in published maps and institutional affiliations. This Springer imprint is published by the registered company Springer Nature Switzerland AG The registered company address is: Gewerbestrasse 11, 6330 Cham, Switzerland

Foreword

It is a great honor to write the Foreword to what will surely become a major contribution to the advance of glass science and engineering throughout the world—the publishing of a long overdue and modern summary of Fiberglass Science and Technology. The goals, scope, and expectations of this book are eloquently and thoroughly stated in the Preface authored by the internationally renowned Editor, Dr. Hong Li. That these objectives are met, and then some, is evidenced by the scholarly material presented in eight chapters by authors from across the globe, all of whom are similarly renowned and highly respected. Rather remarkably, over 1000 references are cited by these authors—a tremendous, timesaving treasure to those involved in the manufacture or scientific investigation of this material. The result of this collective effort is a summary of the latest science and technology on how fiberglass is fabricated, characterized, and utilized and the physical/chemical properties of this material resulting thereof. Of special value is the description offered of batch-to-melt processing—including environmental aspects—which is also undergirded by presentation of state-of-the-art modeling of rate phenomena associated with this process. In view of these remarks, it is confidently predicted that this book will come to be regarded as a milestone in the history of fiberglass and will be read and re-read by scientists, engineers, and educators involved in the manufacture or characterization of this material. Many may even come to regard it as the sine qua non of fiberglass technology. Thus, congratulations are offered to all involved in the writing and publication of this book. The NY State College of Ceramics at Alfred University, Alfred Station, NY, USA

L. David Pye

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Preface

Glass fiber, in both continuous form and discontinuous form, offers countless opportunities in people’s modern life, covering automobile and transportation, renewable energy, construction, chemical industry, electronics, consumer goods, etc. Glass fibers are used as reinforcements for organic matrices as an integral part of composites. Mineral wool fibers are used as a standalone material input for thermal insulation primarily in building materials. Driven by the global demand for cleaner environment, glass fiber with higher specific mechanical properties because of its light weight and unique high thermal insulation over metallic materials of the counterparts provides a wide range of solutions to meet the global call. Fiberglass industry has existed since the 1950s and has accelerated its production technology, capacity, and market applications since the 1990s. The research and development of fiberglass relies heavily on both inorganic and organic chemistries; the former delivers inherent properties for application and high-temperature processing needs and the latter provides the functionalities to bridge glass fiber product to plastic matrix of the composite and downstream process requirements in making the composite components. On the manufacturing technology site, fiberglass production requires a deep understanding of raw materials, energy, batch-to-melt conversion and glass fining, and fiber drawing. It also requires deep technical knowledge of glass volatilization in glass melting to meet emission control requirements. Combining our collective efforts from the pool of international expertise, this book covers relevant topics on fiberglass manufacturing, development and commercial application, fundamental glass science research, physics, fiberglass chemistry and sizing chemistry and usage, and spectroscopic techniques for materials characterization, including glass and glass fiber. The contributors of this monograph have combined decades of expertise and experiences in fiberglass and glass research and development, fiberglass manufacturing processes (operation, thermodynamics, etc.), glass and glass surface chemistry and molecular dynamics modeling of complex glass network structures, organic chemistry in designing fiberglass coating, i.e., sizing, and spectroscopic characterizations of glass and glass fibers, etc.

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Preface

The book consists of eight chapters edited by Hong Li. Chapter 1 gives a broad and comprehensive review of glass fibers (both continuous glass fiber and mineral wool fiber) by Qun Zu, Mette Solvang, and Hong Li. Chapter 2 focuses on the application of spectroscopic techniques in glass and glass fiber studies (Raman spectroscopy by Daniel R. Neuville, Wilfried Blanc, et al.; Nuclear Magnetic Resonance spectroscopy by Thibault Charpentier; Molecular Dynamics Simulations of the glass network and fracture processes by Jincheng Du and Mengguo Ren; and Differential Scanning Calorimetry by Yuanzheng Yue). Chapter 3 details advanced studies in surface chemistry and adsorption on glass fibers by Carlo G. Pantano, Robert A. Schaut, et al. Chapter 4 provides a comprehensive literature and patent reviews on fiberglass sizing by James L. Thomason. Chapter 5 provides thermodynamic descriptions of fiberglass batch-to-melt process by Reinhard Conrad. Chapter 6 details environmental aspects of fiberglass melting by Mathieu Hubert. Chapter 7 provides a physical review of fiberglass forming ability by Yuanzheng Yu. Chapter 8 details the mathematical modeling of rate phenomena in glass melting by Manoj K. Chaudhary. Many of above contributors are active members of Technical Committee 28 (Glass fibers for reinforcement and insulation) of the International Commission on Glass (ICG). The book is a part of the global glass community contributions to the ICG led effort on celebrating the United Nations’ International Year of Glass in 2022. The book is intended for graduate students, researchers, engineers, and professionals for their development in the field of glass fibers and fundamental glass research. The book can be also used as a part of reading materials in a college education program with a focus on glass and glass fibers. There are more than 1100 references cited through the book, which can provide a wealthy literature database for further in-depth study. Dr. Hong Li wishes to express his sincere gratitude to PPG Industries for fiberglass development opportunities and recognitions provided during his tenure between 2000 and 2017 and to Nippon Electric Glass for the new opportunities of fiberglass development since 2017. Dr. Li wishes to thank the following people for providing their invaluable professional and scientific advice through his career: Professor Richard C. Bradt, Professor Minoru Tomozawa, Professor Richard K. Brow, Professor L. David Pye, Dr. Pavel Hrma, Dr. Paul A. Westbrook, and Dr. Joseph S. Hayden. Finally, Dr. Li wishes to thank all the contributors who dedicated their great effort during the manuscript preparation and to Springer’s initiation of the book project and support during the course of the manuscript preparation and publication. Shelby, NC, USA

Hong Li

Contents

1

Commercial Glass Fibers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Qun Zu, Mette Solvang, and Hong Li

2

Structure Characterizations and Molecular Dynamics Simulations of Melt, Glass, and Glass Fibers . . . . . . . . . . . . . . . . . . . Daniel R. Neuville, T. Charpentier, J. C. Du, Y. Z. Yue, Wilfried Blanc, Maria R. Cicconi, Matthieu Lancry, and M. Ren

1

89

3

Surface Chemistry and Adsorption on Glass Fibers . . . . . . . . . . . . . 217 Robert A. Schaut, Victor A. Bakaev, and Carlo G. Pantano

4

Sizing Chemistry of Glass Fibers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 James L. Thomason

5

Fiberglass Batch-to-Melt Process . . . . . . . . . . . . . . . . . . . . . . . . . . . 323 Reinhard Conradt

6

Environmental Aspects of Fiberglass Melting . . . . . . . . . . . . . . . . . . 383 Mathieu Hubert

7

Fiber Forming and Its Impact on Mechanical Properties . . . . . . . . . 455 Yuanzheng Yue

8

Mathematical Modeling of Rate Phenomena in Glass Melting Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483 Manoj K. Choudhary

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541

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About the Editor

Hong Li was trained in the field of materials science with areas of focus in mechanical engineering (BE, Shanghai Maritime University, 1982), ceramic science and engineering (BS, Alfred University, 1987), materials engineering (MS, University of Washington, 1989), and metallurgical engineering (PhD, University of Nevada-Reno, 1992). Between 1992 and 1994, Dr. Li worked at Rensselaer Polytechnic Institute (US) as a postdoctoral research associate, where he conducted research on glasses investigating the mechanical and physical properties of pure silica glass and complex simulated nuclear waste glasses. Dr. Li is currently a senior scientist, working at Nippon Electric Glass (NEG) in US Fiber Glass Division since 2017. Between 2000 and 2017, Dr. Li worked at Fiber Glass Technology Center, PPG Industries (US), and Research and Development Center, SCHOTT North America (US); during these periods he was responsible for the development of various high-performance continuous glass fiber products for composite reinforcement applications (high corrosion resistance, high strength, high modulus, low dielectric property, and high thermal stability) and new laser glasses (broader emission bandwidth or higher repetition rate), respectively. Between 1994 and 2000, Dr. Li first worked at Pacific Northwest National Laboratory under a research fellowship program and later was promoted to senior research scientist, during which period he had various roles and was responsible for evaluating the performance and properties of both simulated high-level and low-level radioactive waste glasses. Dr. Li has a combined experience of more than 28 years in applied glass research and commercial technology development. In 2008, Dr. Li received PPG Industries Innova Award for developing low dielectric constant glass fiber for electronic applications and, in 2012, was awarded a lifetime membership of PPG Collegium for his sustainable contributions in patented fiberglass technologies and commercialization success, including the development of INNOFIBER ® Fiber Glass technology platform. He was a member of the PPG team receiving Ringer Technology Innovation Awards in Shanghai (2013) for PPG’s high modulus INNOFIBER® XM fiberglass development and commercialization in the high-performance wind turbine xi

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About the Editor

blade application. With NEG, Dr. Li has successfully materialized two international licensing projects: INNOFIBER P-CR fiberglass technology for general reinforcement and filtration markets, and INNOFIBER A-LD fiberglass technology for high end electronic application in the growing 5G telecommunication market. Dr. Li was elected a Fellow of the American Ceramic Society (ACerS, 2012) and served as the chair of the Glass and Optical Materials Division, ACerS (2009–2010). Since 2010, Dr. Li has been representing ACerS as a Council Member at International Commission on Glass. Dr. Li co-organized numerous international symposia on fundamental glass science and fiberglass technology, plus giving numerous invited presentations at conferences on fiberglass science and technology. He also serves as a technical referee for multiple glass and materials science journals (Journal of the American Ceramic Society, International Journal of Applied Science, Journal of Non-Crystalline Solids, etc.). Dr. Li co-edited three monographs (Melt Chemistry, Relaxation, and Solidification Kinetics of Glasses, 2004; New Specialty Glasses, 2020; Development History of Ancient Chinese Glass Technology, 2021) and one journal issue (Special Topical Issue on Inorganic Fibers, 2006). Dr. Li also co-authored two chapters (Glass Fibers, ASM Handbook on Composites, 2002; Continuous Glass Fibers for Reinforcement, Encyclopedia of Glass Science, Technology, History and Culture, 2020) and more than 100 technical publications in peer-reviewed journals. Dr. Li is an inventor or co-inventor of more than 110 patents and patent applications worldwide.

Chapter 1

Commercial Glass Fibers Qun Zu, Mette Solvang, and Hong Li

1.1

Overview

The first man-made glass by accident from melting natural sand with natron (natural sodium nitrate) can be dated around 3500 B.C. in Egypt and Eastern Mesopotamia. Numerous artifacts from archology excavations show pottery or glassware (fiancé) wrapped with man-made glass filaments or glass fibers. No specific historical records, but it is not unexpected that the first accidental discovery of making glass fibers coming from stretching a molten glass object. Knowing the glass making process, the early Egyptians would also learn the art making glass filaments or bigger glass fibers, perhaps found it naturally through the process of making glass objects, and subsequently wrap them over clay vessels and fuse glass fibers onto glass vessels for decoration. Venetian glass blowers in the sixteenth and seventeenth centuries used glass fibers to decorate elaborate glass articles. Glass fibers, in a fine textile form, were even used as fabric elements in fashion garments in the late nineteenth century, yet the business was not successful because of its breakage under repetitive folding, especially in washing. Today at least two major categories of glass fibers are industrialized, continuous glass fiber and mineral wool fibers. The former has become the most widely used and cost-effective reinforcing fibers. Early melt spun processes have evolved to today’s large-scale direct melt continuous fiber forming operations. Original E-Glass compositions for glass fibers have grown to include an increasing array of specialty glass

Q. Zu Nanjing Fiberglass Research and Design Institute, Nanjing, China M. Solvang ROCKWOOL International A/S, Hedehusene, Denmark e-mail: [email protected] H. Li (*) Nippon Electric Glass, Shelby, NC, USA © Springer Nature Switzerland AG 2021 H. Li (ed.), Fiberglass Science and Technology, https://doi.org/10.1007/978-3-030-72200-5_1

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Q. Zu et al.

compositions that are targeted for key expanding markets in electronics, transportation, corrosion, construction, and in energy management. Prior to 2000, most major glass fibers manufacturers were concentrated in North America and Western Europe. Today, fiber glass production facilities are flourishing in China and beginning to spread to other regions of the world. It is the intent of this overview to provide insight into the technology that is associated with the continuing success of glass as a reinforcing fiber. Fiber glass technology associated with both material characteristics and manufacturing processes are described at a high level. The industrial mineral wool fiber has become the most widely used as glassy insulation material in which there are two branches, stone wool and glass wool. Mineral wool fibers are typically produced close to where the market demands the most. Traditionally stone wool fibers have been produced in Europe, whereas glass wool fibers typically are produced in North America, France, and the UK. As the need for insulation against cold and hot weather is growing, as well as protection against the spread of fire, the production facilities have moved toward the markets in the Middle East and Asia. In this chapter, these two major glass fiber categories are discussed, firstly continuous fibers and then industrial mineral wool fibers. For both categories their historical development, production process, glass chemistry and commercial status will be discussed as well as their various applications.

1.2

Continuous Glass Fibers

Two key developments around the mid-1930s create the means for glass fiber to become the base of a new industry of composite materials, i.e., organic polymers reinforced with glass fibers, more commonly known as glass fiber reinforced plastic composites (GFRPC). The first was improvement of the continuous glass wool fiber processing under the joint development between the Owens-Illinois Fiberglass Company and Corning Glass Works (now Corning Incorporated). In 1938, Owens Corning Fiberglass Corporation (OC) was established; during the same year, the continuous wool fiber process improvement led the development of continuous E-Glass fiber production. The second was the development of polymeric resin systems by DuPont in 1936 and others that could be combined readily with glass fibers. The GFRPC materials offer key material advantages over conventional metallic materials, including light weight, stiffness and strength, and resistance to corrosion and fatigue. Reinforcement glass fibers or fiberglass can be broadly divided into two categories—general purpose fibers and premium specialty fibers. General purpose glass fibers are known by the designation of E-glass with various compositions and are defined by specific oxide composition ranges according to the standard, ASTM D578 [1]. Historically, E-glass fibers have been predominant in the commercial production of fiber glass products for use as reinforcements in various industrial polymer-matrix composites applications. Other specialty glass fibers that have been

1 Commercial Glass Fibers

3

S

High modulus High dielectric performance Alkaline resistance Acid corrosion resistance Electrical insulation/acid corrosion resistance

Type of Glass Fibers

High strength

R D AR C E-CR E

Good electrical performance and general industry application 1930

1940

1950

1960

1970

1980

1990

2000

2010

2020

Year Fig. 1.1 History of commercial continuous fiber glass development (most active period in development shown and beyond 2015 most intensive research areas projected are -S, -R, and -D glass fibers) and standard nomenclature/classification based on their key properties used in commercial applications. (After Li et al. [3])

used to address unique functionality have low volume in production, including S-Glass, R-Glass, D-Glass, ultrapure silica fibers, and hollow fibers [2]. Continuous glass fibers for composite reinforcement have been categorized by the specific properties required for the end use applications as briefly discussed below. Figure 1.1 highlights the historical timeline of the fiber glass development and commercial use of these major glass fiber types in a chronological order. Tables 1.1 and 1.2 provide further detail on typical oxides and oxide ranges, physical and mechanical properties, and processing related properties. Specific examples of recent developments in the areas of D-, S-, and R-Glass are also included in these tables.

1.2.1

E-Glass

First commercialized in the late 1930s, E-Glass fiber is the most widely used class of fiber glass for GFRPCs [2, 3]. E-Glass is primarily a ternary system of CaO-Al2O3SiO2; B2O3 and F2 are conditionally used, varying between 0 and 10 weight % and 0 to 2 weight %, respectively. For much of its history, E-glass fiber production incorporates B2O3 in commercial compositions at levels of 7–8 weight %. This level provides an optimal balance of melting and fiber forming characteristics, mechanical properties, and electrical properties. Over time, however, increasingly restrictive environmental emission requirements for particulates have drove investment costs up for installation of emission control systems. Countries, such as Canada and Norway, have been leaders in the push to improve environmental conditions, leading to the introduction of the first boron-free commercial E-glass fiber production. The type of glass fiber has been also found to have excellent corrosion resistance under

TiO2 Na2O is greater than K2O

64–66 55–65 52–57

S-Glass S (derivative I) S (derivative II)

b

a

SiO2 (wt%) 52–62 67.0 53–65 61–71 72–76 52–60 50–60 60–77 45–65 58–60 56–65 58–63 48–54

Fiber glass E-Glass including E-CR C (China) C (Europe) AR-Glass D-Glass D (derivative I) D (derivative II) D (derivative III) D (derivative IV) R-Glass R (derivative I) R (derivative II) R (derivative III)

24–25 23–26 20–25

Al2O3 (wt%) 12–16 6.2 3.8–16 0–3 0–1 10–18 10–18 9–15 9–20 23–26 12–20 18–23 16–22 9.5–10 9–15 10–14