ch9 composites

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Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. Chapter 9 Composite Materials: Structure, General Properties and Applications

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Page 1: Ch9 composites

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Chapter 9Composite Materials: Structure,

General Properties and Applications

Page 2: Ch9 composites

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Boeing 757-200

Figure 9.1 Application of advanced composite materials in Boeing 757-200commercial aircraft. Source: Courtesy of Boeing Commercial Airplane Company.

Page 3: Ch9 composites

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Methods of Reinforcing Plastics

Figure 9.2 Schematic illustration of methods of reinforcing plastics (matrix) with (a)particles, (b) short or long fibers or flakes, and (c) continuous fibers. The laminatestructures shown in (d) can be produced from layers of continuous fibers or sandwichstructures using a foam or honeycomb core (see also Fig. 16.50).

Page 4: Ch9 composites

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Characteristics of Composite Materials

Page 5: Ch9 composites

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Tensile Strength and Modulus for Fibers in Plastic

Figure 9.3 Specific tensile strength (tensile strength-to-density ratio) and specifictensile modulus (modulus of elasticity-to-density ratio) for various fibers used inreinforced plastics. Note the wide range of specific strengths and stiffnesses available.

Page 6: Ch9 composites

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Properties of Reinforcing Fibers

Page 7: Ch9 composites

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Cross-sections of Fiber-reinforced Materials

Figure 9.4 (a) Cross-section of a tennis racket, showing graphite and aramid (Kevlar)reinforcing fibers. Source: Courtesy of J. Dvorak, Mercury Marine Corporation and F. Garret,Wilson Sporting Goods Co. (b) Cross-section of boron fiber-reinforced composite material

Page 8: Ch9 composites

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Effect of Fiber Type on Properties of Fiber-reinforced Nylon

Figure 9.5 Theeffect of type offiber on variousproperties of fiber-reinforced nylon(6,6). Source:Courtesy of NASA.

Page 9: Ch9 composites

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Fracture Surfaces of Fiber-reinforced Epoxy Composites

(a) (b)Figure 9.6 (a) Fracture surface of a glass fiber-reinforced epoxy composite. The fibersare 10µm (400µin.) in diameter and have random orientation. (b) Fracture surface of agraphite fiber-reinforced epoxy composite. The fibers, 9 µm to 11µm in diameter, are inbundles and are all aligned in the same direction. Source: Courtesy of L.J. Broutman

Page 10: Ch9 composites

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Mechanical Properties of Reinforced Plastics

Figure 9.7 The tensile strength of glass-reinforcedpolyester as a function of fiber content and fiberdirection in the matrix.

!

Load fraction of fibers :

Pf

Pm=Af E f

AmEm

Elastic modulus of composite :

Ec = xE f + 1" x( )Em

Page 11: Ch9 composites

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Composite Sailboard Cross-section

Figure 9.8 Cross-section of a composite sailboard, an example of advancedmaterials construction. Source: K. Easterline, Tomorrow’s Materials (2nd ed.),p. 133. Institute of Metals, 1990.

Page 12: Ch9 composites

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Metal-Matrix Composite Parts

Figure 9.10 Examples of metal-matrix composite parts.Source: Courtesy of Metal Matrix Cast Composites, LLC.

Page 13: Ch9 composites

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Metal-Matrix Composite Materials and Applications

Page 14: Ch9 composites

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Metal Matrix Automotive Brake Caliper

Figure 9.11 Aluminum-matrix compositebrake caliper using nanocrystallynealumina fiber reinforcement. Source:Courtesy of 3M Corp.