introduction and classification of composites

44
Composite Composite Materials Materials P rof.V.Alfred Franklin., rof.V.Alfred Franklin., St.Xavier’s Catholic College of St.Xavier’s Catholic College of Engineering Engineering Nagercoil, India. Nagercoil, India.

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Page 1: Introduction and Classification of Composites

ME 1014 ME 1014 Composite MaterialsComposite Materials

PProfVAlfred Franklin rofVAlfred Franklin StXavierrsquos Catholic College of EngineeringStXavierrsquos Catholic College of Engineering

Nagercoil IndiaNagercoil India

Composite MaterialComposite Material Two inherently different materials that when combined Two inherently different materials that when combined together produce a material with properties that exceed together produce a material with properties that exceed the constituent materialsthe constituent materials

Any combination of two or more different materials at the Any combination of two or more different materials at the macroscopic levelmacroscopic level

The constituents retain their identities ie they do not dissolve or merge into each other although they act in concert

Composites Artificially produced multiphase materials

Composite MaterialComposite Material

Composites A judicious combination of two or more materials that produces a synergistic effect

A material system composed of two or more physically distinct phases whose combination produces aggregate properties that are different from those of its constituents

Phases of Composites

Matrix Phase continuous phase surrounds other phase (eg metal (Cu Al Ti Nihellip) ceramic (SiChellip) or polymer (Thermosets thermoplastics Elastomers)

Reinforcement Phase dispersed phase discontinuous phase (eg Fibers Particles or Flakes)

1048707 rarr Interface between matrix and reinforcementInterfacial properties - the interface may be regarded as a third phase

Examplesndash Straw in mudndash Wood (cellulose fibers in hemicellulose and lignin)ndash Bones (soft protein collagen and hard apatite minerals)ndash Pearlite (ferrite and cementite)

Micro mechanics Macro mechanics

Major ConstituentsMajor Constituents

FiberMatrixFillersCoupling agentsColorants

FIBERSFIBERS

Principle Load carrying member

Main constituent and they occupy largest volume fraction

Diameter of a single fiber is about 10 microns

They may be continuous or discontinuous in length

TYPES OF GLASS FIBERTYPES OF GLASS FIBER E-Glass ndash E stands for electricalE-Glass ndash E stands for electrical S-Glass ndash S stands for high silica contentS-Glass ndash S stands for high silica content

High thermal expansion coefficientHigh thermal expansion coefficient High fatigue strengthHigh fatigue strength

C-Glass ndash C stands for CorrosionC-Glass ndash C stands for Corrosion Used in Chemical applicationsUsed in Chemical applications Storage tanksStorage tanks

R-Glass ndash R stands for RigidR-Glass ndash R stands for Rigid Structural applicationsStructural applications

D-Glass ndash D stands for DielectricD-Glass ndash D stands for Dielectric Low dielectric constantsLow dielectric constants

A-Glass ndash A Stands for appearanceA-Glass ndash A Stands for appearance To improve surface appearanceTo improve surface appearance For ornamental worksFor ornamental works

E-CR Glass ndash E-CR stands for Electrical and E-CR Glass ndash E-CR stands for Electrical and corrosion resistancecorrosion resistance

AR Glass ndash AR stands for Alkali resistanceAR Glass ndash AR stands for Alkali resistance

bull Critical fiber length for effective stiffening amp strengthening

fiber length15

fdc

fiber diameter

shear strength offiber-matrix interface

fiber strength in tension

Efficiency fiber lengthEfficiency fiber length

(x)

7

fiber length 15

fdc

Shorter thicker fiber

fiber length 15

fdc

(x)

Longer thinner fiber

Poorer fiber efficiency Better fiber efficiency

Why are Fibers of a Thin Diameter

1 Thinner fiber has higher ultimate strength because less chance

for inherent flaws Similar phenomenon in metals and alloys(Strength of a thin wire can be higher than its bulk material)

2 For the same volume of fibers thinner fibers has largersurface area thus has stronger bond with matrix (The totalsurface area of fibers is inversely proportional to the

diameterof fibers)

3 Thinner fiber has larger flexibility ( 1(EI)) and therefore isable to be bent without breaking (Woven fabric performs canbe made before impregnated with polymer matrix)

Composite Strength Longitudinal LoadingComposite Strength Longitudinal Loading

Continuous fibersContinuous fibers - - Estimate fiber-reinforced composite Estimate fiber-reinforced composite strength for long continuous fibers in a matrixstrength for long continuous fibers in a matrix

Longitudinal deformationLongitudinal deformation

cc = = mmVVmm + + ffVVff butbut cc = = mm = = ff volume fractionvolume fraction isostrainisostrain

Ec = Em Vm + EfVf longitudinal (extensional)

modulus

mm

ff

m

f

VE

VE

F

F f = fiber

m = matrixC-composite

Remembering E = and note this model corresponds to the ldquoupper boundrdquo for particulate composites

Matrix Matrix RResinsesins

- - The resin or The resin or polymerpolymer is the ldquogluerdquo that is the ldquogluerdquo that

holds the composite togetherholds the composite together

-The primary functions of the resin are to -The primary functions of the resin are to transfer stress between the reinforcing fiberstransfer stress between the reinforcing fibers

Examples Polyester Epoxy Vinyl Ester PolyurethaneExamples Polyester Epoxy Vinyl Ester Polyurethane

Transfer stresses between the fibers Provide a barrier against an adverse

environment Protect the surface of the fibers from

mechanical abrasion Determine inter-laminar shear strength Determine damage tolerance of composites Determine in-plane shear strength Determine the processibility of composites Determine heat resistance of composites

Role of Matrices in Composites

Role of MatrixRole of Matrix The primary roles of the matrix alloy then are to provideefficient transfer of load to the fibers and to blunt cracks inthe event that fiber failure occurs and so the matrix alloy forcontinuously reinforced composites may be chosen more fortoughness than for strength

On this basis lower strength more ductile and tougher matrix alloys may be utilized in continuously reinforced

composites

For discontinuously reinforced composites the matrix may govern composite strength-Then the choice of matrix will be influenced by consideration of the required composite strength and higher strength matrix alloys may be required

Functions of Matrix

Holds the fibres together Protects the fibres from environment

Distributes the loads evenly between fibres so that all fibres are subjected to the same amount of strain

Enhances transverse properties of a laminate Improves impact and fracture resistance of a component

Helps to avoid propagation of crack growth through the fibres by providing alternate failure path along the interface between the fibres and the matrix

Carry inter-laminar shear

Desired Properties of a Matrix

Reduced moisture absorption

Low shrinkage

Low coefficient of thermal expansion

Good flow characteristics so that it penetrates the fibre bundles completely and eliminates voids during the compactingcuring process

Must be elastic to transfer load to fibres

Desired Properties of a Matrix

Reasonable strength modulus and elongation (elongationshould be greater than fibre)

Strength at elevated temperature (depending on application)

Low temperature capability (depending on application)

Excellent chemical resistance (depending on application)

Should be easily processable into the final composite shape

Dimensional stability (maintains its shape)

FILLERSFILLERS

Control Compositesrsquo CostControl Compositesrsquo Cost Improved Mechanical PropertiesImproved Mechanical Properties Improved Chemical PropertiesImproved Chemical Properties Reduced Creep amp ShrinkageReduced Creep amp Shrinkage Low Tensile StrengthLow Tensile Strength Fire Retardant amp Chemical ResistantFire Retardant amp Chemical Resistant

TYPES OF FILLERTYPES OF FILLER Calcium CarbonateCalcium Carbonate KaolinKaolin Alumina TrihydrateAlumina Trihydrate Mica FeldsparMica Feldspar WollastoniteWollastonite Silica Talc GlassSilica Talc Glass

ADDITIVESADDITIVES

Improved Material PropertiesImproved Material Properties AestheticsAesthetics Enhanced WorkabilityEnhanced Workability Improved PerformanceImproved Performance

ADDITIVE TYPESADDITIVE TYPES

CatalystsCatalysts PromotersPromoters InhibitorsInhibitors Coloring DyesColoring Dyes Releasing AgentsReleasing Agents Antistatic AgentsAntistatic Agents Foaming AgentsFoaming Agents

Composites OfferComposites Offer High Strength to weight ratioHigh Strength to weight ratioHigh Stiffness to weight ratioHigh Stiffness to weight ratioHigh Modulus to weight ratioHigh Modulus to weight ratioLight WeightLight WeightDirectional strength Directional strength Corrosion resistance Corrosion resistance Weather resistance Weather resistance Dimensional stability Dimensional stability -low thermal conductivity -low thermal conductivity

-low -low coefficient of thermal expansioncoefficient of thermal expansion Radar transparencyRadar transparencyNon-magnetic Non-magnetic High impact strength High impact strength High High dielectricdielectric strength (insulator) strength (insulator) Low maintenance Low maintenance Long term durability Long term durability Part consolidation Part consolidation Small to large part geometry possible Small to large part geometry possible Tailored surface finish Tailored surface finish Design FlexibilityDesign Flexibility

Property comparisonProperty comparison

Material

Tensile modulus

(E) ( 2 mGN )

Tensile strength( u )

( 2 mGN )

Density ( )

( 3 cmg )

Specific modulus

( E )

Specific strength ( u )

E-Glass 724 53 254 285 138

Graphite 3900 21 190 2050 11

Boron 3850 28 263 1460 11

Kevlar ndash 49 130 28 150 87 187

Steel 210 034 ndash 21 78 269 0043 ndash

027

Aluminum alloys

70 014 ndash 062 27 259 0052 ndash

023

CompositeComposite strengthstrength depends on the following depends on the following factorsfactors

Inherent fiber Inherent fiber strength Fiber length strength Fiber length Number of flawsNumber of flaws

Fiber shape Fiber shape The bonding of the The bonding of the

fiber (equally stress fiber (equally stress distribution)distribution)

Voids Voids Moisture (coupling Moisture (coupling

agents)agents)

Classification of Composite MaterialsClassification of Composite Materials

11 Traditional compositesTraditional composites ndash composite materials ndash composite materials that occur in nature or have been produced by that occur in nature or have been produced by civilizations for many years civilizations for many years ExamplesExamples wood wood (cellulose fibers in lignin

matrix) concrete asphalt concrete asphalt

22 Synthetic compositesSynthetic composites - modern material - modern material systems normally associated with the systems normally associated with the manufacturing industries in which the manufacturing industries in which the components are first produced separately and components are first produced separately and then combined in a controlled way to achieve then combined in a controlled way to achieve the desired structure properties and part the desired structure properties and part geometry geometry

Classification of Classification of SyntheticSynthetic Composites Composites Based on MatrixBased on Matrix

Matrix

Reinforcement

Metal Ceramic Polymer

Metal Powder metallurgy parts ndash combining immiscible metals

Cermets (ceramic-metal composite)

Brake pads

Ceramic Cermets TiC TiCNCemented carbides ndash used in toolsFiber-reinforced metals

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer Kevlar fibers in an epoxy matrix

Elemental (Carbon Boron etc)

Fiber reinforced metalsAuto partsaerospace

Rubber with carbon (tires)Boron Carbon reinforced plastics

MMCrsquos CMCrsquos PMCrsquosMetal Matrix Composites Ceramic Matrix Comprsquos Polymer Matrix Comprsquos

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 2: Introduction and Classification of Composites

Composite MaterialComposite Material Two inherently different materials that when combined Two inherently different materials that when combined together produce a material with properties that exceed together produce a material with properties that exceed the constituent materialsthe constituent materials

Any combination of two or more different materials at the Any combination of two or more different materials at the macroscopic levelmacroscopic level

The constituents retain their identities ie they do not dissolve or merge into each other although they act in concert

Composites Artificially produced multiphase materials

Composite MaterialComposite Material

Composites A judicious combination of two or more materials that produces a synergistic effect

A material system composed of two or more physically distinct phases whose combination produces aggregate properties that are different from those of its constituents

Phases of Composites

Matrix Phase continuous phase surrounds other phase (eg metal (Cu Al Ti Nihellip) ceramic (SiChellip) or polymer (Thermosets thermoplastics Elastomers)

Reinforcement Phase dispersed phase discontinuous phase (eg Fibers Particles or Flakes)

1048707 rarr Interface between matrix and reinforcementInterfacial properties - the interface may be regarded as a third phase

Examplesndash Straw in mudndash Wood (cellulose fibers in hemicellulose and lignin)ndash Bones (soft protein collagen and hard apatite minerals)ndash Pearlite (ferrite and cementite)

Micro mechanics Macro mechanics

Major ConstituentsMajor Constituents

FiberMatrixFillersCoupling agentsColorants

FIBERSFIBERS

Principle Load carrying member

Main constituent and they occupy largest volume fraction

Diameter of a single fiber is about 10 microns

They may be continuous or discontinuous in length

TYPES OF GLASS FIBERTYPES OF GLASS FIBER E-Glass ndash E stands for electricalE-Glass ndash E stands for electrical S-Glass ndash S stands for high silica contentS-Glass ndash S stands for high silica content

High thermal expansion coefficientHigh thermal expansion coefficient High fatigue strengthHigh fatigue strength

C-Glass ndash C stands for CorrosionC-Glass ndash C stands for Corrosion Used in Chemical applicationsUsed in Chemical applications Storage tanksStorage tanks

R-Glass ndash R stands for RigidR-Glass ndash R stands for Rigid Structural applicationsStructural applications

D-Glass ndash D stands for DielectricD-Glass ndash D stands for Dielectric Low dielectric constantsLow dielectric constants

A-Glass ndash A Stands for appearanceA-Glass ndash A Stands for appearance To improve surface appearanceTo improve surface appearance For ornamental worksFor ornamental works

E-CR Glass ndash E-CR stands for Electrical and E-CR Glass ndash E-CR stands for Electrical and corrosion resistancecorrosion resistance

AR Glass ndash AR stands for Alkali resistanceAR Glass ndash AR stands for Alkali resistance

bull Critical fiber length for effective stiffening amp strengthening

fiber length15

fdc

fiber diameter

shear strength offiber-matrix interface

fiber strength in tension

Efficiency fiber lengthEfficiency fiber length

(x)

7

fiber length 15

fdc

Shorter thicker fiber

fiber length 15

fdc

(x)

Longer thinner fiber

Poorer fiber efficiency Better fiber efficiency

Why are Fibers of a Thin Diameter

1 Thinner fiber has higher ultimate strength because less chance

for inherent flaws Similar phenomenon in metals and alloys(Strength of a thin wire can be higher than its bulk material)

2 For the same volume of fibers thinner fibers has largersurface area thus has stronger bond with matrix (The totalsurface area of fibers is inversely proportional to the

diameterof fibers)

3 Thinner fiber has larger flexibility ( 1(EI)) and therefore isable to be bent without breaking (Woven fabric performs canbe made before impregnated with polymer matrix)

Composite Strength Longitudinal LoadingComposite Strength Longitudinal Loading

Continuous fibersContinuous fibers - - Estimate fiber-reinforced composite Estimate fiber-reinforced composite strength for long continuous fibers in a matrixstrength for long continuous fibers in a matrix

Longitudinal deformationLongitudinal deformation

cc = = mmVVmm + + ffVVff butbut cc = = mm = = ff volume fractionvolume fraction isostrainisostrain

Ec = Em Vm + EfVf longitudinal (extensional)

modulus

mm

ff

m

f

VE

VE

F

F f = fiber

m = matrixC-composite

Remembering E = and note this model corresponds to the ldquoupper boundrdquo for particulate composites

Matrix Matrix RResinsesins

- - The resin or The resin or polymerpolymer is the ldquogluerdquo that is the ldquogluerdquo that

holds the composite togetherholds the composite together

-The primary functions of the resin are to -The primary functions of the resin are to transfer stress between the reinforcing fiberstransfer stress between the reinforcing fibers

Examples Polyester Epoxy Vinyl Ester PolyurethaneExamples Polyester Epoxy Vinyl Ester Polyurethane

Transfer stresses between the fibers Provide a barrier against an adverse

environment Protect the surface of the fibers from

mechanical abrasion Determine inter-laminar shear strength Determine damage tolerance of composites Determine in-plane shear strength Determine the processibility of composites Determine heat resistance of composites

Role of Matrices in Composites

Role of MatrixRole of Matrix The primary roles of the matrix alloy then are to provideefficient transfer of load to the fibers and to blunt cracks inthe event that fiber failure occurs and so the matrix alloy forcontinuously reinforced composites may be chosen more fortoughness than for strength

On this basis lower strength more ductile and tougher matrix alloys may be utilized in continuously reinforced

composites

For discontinuously reinforced composites the matrix may govern composite strength-Then the choice of matrix will be influenced by consideration of the required composite strength and higher strength matrix alloys may be required

Functions of Matrix

Holds the fibres together Protects the fibres from environment

Distributes the loads evenly between fibres so that all fibres are subjected to the same amount of strain

Enhances transverse properties of a laminate Improves impact and fracture resistance of a component

Helps to avoid propagation of crack growth through the fibres by providing alternate failure path along the interface between the fibres and the matrix

Carry inter-laminar shear

Desired Properties of a Matrix

Reduced moisture absorption

Low shrinkage

Low coefficient of thermal expansion

Good flow characteristics so that it penetrates the fibre bundles completely and eliminates voids during the compactingcuring process

Must be elastic to transfer load to fibres

Desired Properties of a Matrix

Reasonable strength modulus and elongation (elongationshould be greater than fibre)

Strength at elevated temperature (depending on application)

Low temperature capability (depending on application)

Excellent chemical resistance (depending on application)

Should be easily processable into the final composite shape

Dimensional stability (maintains its shape)

FILLERSFILLERS

Control Compositesrsquo CostControl Compositesrsquo Cost Improved Mechanical PropertiesImproved Mechanical Properties Improved Chemical PropertiesImproved Chemical Properties Reduced Creep amp ShrinkageReduced Creep amp Shrinkage Low Tensile StrengthLow Tensile Strength Fire Retardant amp Chemical ResistantFire Retardant amp Chemical Resistant

TYPES OF FILLERTYPES OF FILLER Calcium CarbonateCalcium Carbonate KaolinKaolin Alumina TrihydrateAlumina Trihydrate Mica FeldsparMica Feldspar WollastoniteWollastonite Silica Talc GlassSilica Talc Glass

ADDITIVESADDITIVES

Improved Material PropertiesImproved Material Properties AestheticsAesthetics Enhanced WorkabilityEnhanced Workability Improved PerformanceImproved Performance

ADDITIVE TYPESADDITIVE TYPES

CatalystsCatalysts PromotersPromoters InhibitorsInhibitors Coloring DyesColoring Dyes Releasing AgentsReleasing Agents Antistatic AgentsAntistatic Agents Foaming AgentsFoaming Agents

Composites OfferComposites Offer High Strength to weight ratioHigh Strength to weight ratioHigh Stiffness to weight ratioHigh Stiffness to weight ratioHigh Modulus to weight ratioHigh Modulus to weight ratioLight WeightLight WeightDirectional strength Directional strength Corrosion resistance Corrosion resistance Weather resistance Weather resistance Dimensional stability Dimensional stability -low thermal conductivity -low thermal conductivity

-low -low coefficient of thermal expansioncoefficient of thermal expansion Radar transparencyRadar transparencyNon-magnetic Non-magnetic High impact strength High impact strength High High dielectricdielectric strength (insulator) strength (insulator) Low maintenance Low maintenance Long term durability Long term durability Part consolidation Part consolidation Small to large part geometry possible Small to large part geometry possible Tailored surface finish Tailored surface finish Design FlexibilityDesign Flexibility

Property comparisonProperty comparison

Material

Tensile modulus

(E) ( 2 mGN )

Tensile strength( u )

( 2 mGN )

Density ( )

( 3 cmg )

Specific modulus

( E )

Specific strength ( u )

E-Glass 724 53 254 285 138

Graphite 3900 21 190 2050 11

Boron 3850 28 263 1460 11

Kevlar ndash 49 130 28 150 87 187

Steel 210 034 ndash 21 78 269 0043 ndash

027

Aluminum alloys

70 014 ndash 062 27 259 0052 ndash

023

CompositeComposite strengthstrength depends on the following depends on the following factorsfactors

Inherent fiber Inherent fiber strength Fiber length strength Fiber length Number of flawsNumber of flaws

Fiber shape Fiber shape The bonding of the The bonding of the

fiber (equally stress fiber (equally stress distribution)distribution)

Voids Voids Moisture (coupling Moisture (coupling

agents)agents)

Classification of Composite MaterialsClassification of Composite Materials

11 Traditional compositesTraditional composites ndash composite materials ndash composite materials that occur in nature or have been produced by that occur in nature or have been produced by civilizations for many years civilizations for many years ExamplesExamples wood wood (cellulose fibers in lignin

matrix) concrete asphalt concrete asphalt

22 Synthetic compositesSynthetic composites - modern material - modern material systems normally associated with the systems normally associated with the manufacturing industries in which the manufacturing industries in which the components are first produced separately and components are first produced separately and then combined in a controlled way to achieve then combined in a controlled way to achieve the desired structure properties and part the desired structure properties and part geometry geometry

Classification of Classification of SyntheticSynthetic Composites Composites Based on MatrixBased on Matrix

Matrix

Reinforcement

Metal Ceramic Polymer

Metal Powder metallurgy parts ndash combining immiscible metals

Cermets (ceramic-metal composite)

Brake pads

Ceramic Cermets TiC TiCNCemented carbides ndash used in toolsFiber-reinforced metals

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer Kevlar fibers in an epoxy matrix

Elemental (Carbon Boron etc)

Fiber reinforced metalsAuto partsaerospace

Rubber with carbon (tires)Boron Carbon reinforced plastics

MMCrsquos CMCrsquos PMCrsquosMetal Matrix Composites Ceramic Matrix Comprsquos Polymer Matrix Comprsquos

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 3: Introduction and Classification of Composites

Composite MaterialComposite Material

Composites A judicious combination of two or more materials that produces a synergistic effect

A material system composed of two or more physically distinct phases whose combination produces aggregate properties that are different from those of its constituents

Phases of Composites

Matrix Phase continuous phase surrounds other phase (eg metal (Cu Al Ti Nihellip) ceramic (SiChellip) or polymer (Thermosets thermoplastics Elastomers)

Reinforcement Phase dispersed phase discontinuous phase (eg Fibers Particles or Flakes)

1048707 rarr Interface between matrix and reinforcementInterfacial properties - the interface may be regarded as a third phase

Examplesndash Straw in mudndash Wood (cellulose fibers in hemicellulose and lignin)ndash Bones (soft protein collagen and hard apatite minerals)ndash Pearlite (ferrite and cementite)

Micro mechanics Macro mechanics

Major ConstituentsMajor Constituents

FiberMatrixFillersCoupling agentsColorants

FIBERSFIBERS

Principle Load carrying member

Main constituent and they occupy largest volume fraction

Diameter of a single fiber is about 10 microns

They may be continuous or discontinuous in length

TYPES OF GLASS FIBERTYPES OF GLASS FIBER E-Glass ndash E stands for electricalE-Glass ndash E stands for electrical S-Glass ndash S stands for high silica contentS-Glass ndash S stands for high silica content

High thermal expansion coefficientHigh thermal expansion coefficient High fatigue strengthHigh fatigue strength

C-Glass ndash C stands for CorrosionC-Glass ndash C stands for Corrosion Used in Chemical applicationsUsed in Chemical applications Storage tanksStorage tanks

R-Glass ndash R stands for RigidR-Glass ndash R stands for Rigid Structural applicationsStructural applications

D-Glass ndash D stands for DielectricD-Glass ndash D stands for Dielectric Low dielectric constantsLow dielectric constants

A-Glass ndash A Stands for appearanceA-Glass ndash A Stands for appearance To improve surface appearanceTo improve surface appearance For ornamental worksFor ornamental works

E-CR Glass ndash E-CR stands for Electrical and E-CR Glass ndash E-CR stands for Electrical and corrosion resistancecorrosion resistance

AR Glass ndash AR stands for Alkali resistanceAR Glass ndash AR stands for Alkali resistance

bull Critical fiber length for effective stiffening amp strengthening

fiber length15

fdc

fiber diameter

shear strength offiber-matrix interface

fiber strength in tension

Efficiency fiber lengthEfficiency fiber length

(x)

7

fiber length 15

fdc

Shorter thicker fiber

fiber length 15

fdc

(x)

Longer thinner fiber

Poorer fiber efficiency Better fiber efficiency

Why are Fibers of a Thin Diameter

1 Thinner fiber has higher ultimate strength because less chance

for inherent flaws Similar phenomenon in metals and alloys(Strength of a thin wire can be higher than its bulk material)

2 For the same volume of fibers thinner fibers has largersurface area thus has stronger bond with matrix (The totalsurface area of fibers is inversely proportional to the

diameterof fibers)

3 Thinner fiber has larger flexibility ( 1(EI)) and therefore isable to be bent without breaking (Woven fabric performs canbe made before impregnated with polymer matrix)

Composite Strength Longitudinal LoadingComposite Strength Longitudinal Loading

Continuous fibersContinuous fibers - - Estimate fiber-reinforced composite Estimate fiber-reinforced composite strength for long continuous fibers in a matrixstrength for long continuous fibers in a matrix

Longitudinal deformationLongitudinal deformation

cc = = mmVVmm + + ffVVff butbut cc = = mm = = ff volume fractionvolume fraction isostrainisostrain

Ec = Em Vm + EfVf longitudinal (extensional)

modulus

mm

ff

m

f

VE

VE

F

F f = fiber

m = matrixC-composite

Remembering E = and note this model corresponds to the ldquoupper boundrdquo for particulate composites

Matrix Matrix RResinsesins

- - The resin or The resin or polymerpolymer is the ldquogluerdquo that is the ldquogluerdquo that

holds the composite togetherholds the composite together

-The primary functions of the resin are to -The primary functions of the resin are to transfer stress between the reinforcing fiberstransfer stress between the reinforcing fibers

Examples Polyester Epoxy Vinyl Ester PolyurethaneExamples Polyester Epoxy Vinyl Ester Polyurethane

Transfer stresses between the fibers Provide a barrier against an adverse

environment Protect the surface of the fibers from

mechanical abrasion Determine inter-laminar shear strength Determine damage tolerance of composites Determine in-plane shear strength Determine the processibility of composites Determine heat resistance of composites

Role of Matrices in Composites

Role of MatrixRole of Matrix The primary roles of the matrix alloy then are to provideefficient transfer of load to the fibers and to blunt cracks inthe event that fiber failure occurs and so the matrix alloy forcontinuously reinforced composites may be chosen more fortoughness than for strength

On this basis lower strength more ductile and tougher matrix alloys may be utilized in continuously reinforced

composites

For discontinuously reinforced composites the matrix may govern composite strength-Then the choice of matrix will be influenced by consideration of the required composite strength and higher strength matrix alloys may be required

Functions of Matrix

Holds the fibres together Protects the fibres from environment

Distributes the loads evenly between fibres so that all fibres are subjected to the same amount of strain

Enhances transverse properties of a laminate Improves impact and fracture resistance of a component

Helps to avoid propagation of crack growth through the fibres by providing alternate failure path along the interface between the fibres and the matrix

Carry inter-laminar shear

Desired Properties of a Matrix

Reduced moisture absorption

Low shrinkage

Low coefficient of thermal expansion

Good flow characteristics so that it penetrates the fibre bundles completely and eliminates voids during the compactingcuring process

Must be elastic to transfer load to fibres

Desired Properties of a Matrix

Reasonable strength modulus and elongation (elongationshould be greater than fibre)

Strength at elevated temperature (depending on application)

Low temperature capability (depending on application)

Excellent chemical resistance (depending on application)

Should be easily processable into the final composite shape

Dimensional stability (maintains its shape)

FILLERSFILLERS

Control Compositesrsquo CostControl Compositesrsquo Cost Improved Mechanical PropertiesImproved Mechanical Properties Improved Chemical PropertiesImproved Chemical Properties Reduced Creep amp ShrinkageReduced Creep amp Shrinkage Low Tensile StrengthLow Tensile Strength Fire Retardant amp Chemical ResistantFire Retardant amp Chemical Resistant

TYPES OF FILLERTYPES OF FILLER Calcium CarbonateCalcium Carbonate KaolinKaolin Alumina TrihydrateAlumina Trihydrate Mica FeldsparMica Feldspar WollastoniteWollastonite Silica Talc GlassSilica Talc Glass

ADDITIVESADDITIVES

Improved Material PropertiesImproved Material Properties AestheticsAesthetics Enhanced WorkabilityEnhanced Workability Improved PerformanceImproved Performance

ADDITIVE TYPESADDITIVE TYPES

CatalystsCatalysts PromotersPromoters InhibitorsInhibitors Coloring DyesColoring Dyes Releasing AgentsReleasing Agents Antistatic AgentsAntistatic Agents Foaming AgentsFoaming Agents

Composites OfferComposites Offer High Strength to weight ratioHigh Strength to weight ratioHigh Stiffness to weight ratioHigh Stiffness to weight ratioHigh Modulus to weight ratioHigh Modulus to weight ratioLight WeightLight WeightDirectional strength Directional strength Corrosion resistance Corrosion resistance Weather resistance Weather resistance Dimensional stability Dimensional stability -low thermal conductivity -low thermal conductivity

-low -low coefficient of thermal expansioncoefficient of thermal expansion Radar transparencyRadar transparencyNon-magnetic Non-magnetic High impact strength High impact strength High High dielectricdielectric strength (insulator) strength (insulator) Low maintenance Low maintenance Long term durability Long term durability Part consolidation Part consolidation Small to large part geometry possible Small to large part geometry possible Tailored surface finish Tailored surface finish Design FlexibilityDesign Flexibility

Property comparisonProperty comparison

Material

Tensile modulus

(E) ( 2 mGN )

Tensile strength( u )

( 2 mGN )

Density ( )

( 3 cmg )

Specific modulus

( E )

Specific strength ( u )

E-Glass 724 53 254 285 138

Graphite 3900 21 190 2050 11

Boron 3850 28 263 1460 11

Kevlar ndash 49 130 28 150 87 187

Steel 210 034 ndash 21 78 269 0043 ndash

027

Aluminum alloys

70 014 ndash 062 27 259 0052 ndash

023

CompositeComposite strengthstrength depends on the following depends on the following factorsfactors

Inherent fiber Inherent fiber strength Fiber length strength Fiber length Number of flawsNumber of flaws

Fiber shape Fiber shape The bonding of the The bonding of the

fiber (equally stress fiber (equally stress distribution)distribution)

Voids Voids Moisture (coupling Moisture (coupling

agents)agents)

Classification of Composite MaterialsClassification of Composite Materials

11 Traditional compositesTraditional composites ndash composite materials ndash composite materials that occur in nature or have been produced by that occur in nature or have been produced by civilizations for many years civilizations for many years ExamplesExamples wood wood (cellulose fibers in lignin

matrix) concrete asphalt concrete asphalt

22 Synthetic compositesSynthetic composites - modern material - modern material systems normally associated with the systems normally associated with the manufacturing industries in which the manufacturing industries in which the components are first produced separately and components are first produced separately and then combined in a controlled way to achieve then combined in a controlled way to achieve the desired structure properties and part the desired structure properties and part geometry geometry

Classification of Classification of SyntheticSynthetic Composites Composites Based on MatrixBased on Matrix

Matrix

Reinforcement

Metal Ceramic Polymer

Metal Powder metallurgy parts ndash combining immiscible metals

Cermets (ceramic-metal composite)

Brake pads

Ceramic Cermets TiC TiCNCemented carbides ndash used in toolsFiber-reinforced metals

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer Kevlar fibers in an epoxy matrix

Elemental (Carbon Boron etc)

Fiber reinforced metalsAuto partsaerospace

Rubber with carbon (tires)Boron Carbon reinforced plastics

MMCrsquos CMCrsquos PMCrsquosMetal Matrix Composites Ceramic Matrix Comprsquos Polymer Matrix Comprsquos

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 4: Introduction and Classification of Composites

Phases of Composites

Matrix Phase continuous phase surrounds other phase (eg metal (Cu Al Ti Nihellip) ceramic (SiChellip) or polymer (Thermosets thermoplastics Elastomers)

Reinforcement Phase dispersed phase discontinuous phase (eg Fibers Particles or Flakes)

1048707 rarr Interface between matrix and reinforcementInterfacial properties - the interface may be regarded as a third phase

Examplesndash Straw in mudndash Wood (cellulose fibers in hemicellulose and lignin)ndash Bones (soft protein collagen and hard apatite minerals)ndash Pearlite (ferrite and cementite)

Micro mechanics Macro mechanics

Major ConstituentsMajor Constituents

FiberMatrixFillersCoupling agentsColorants

FIBERSFIBERS

Principle Load carrying member

Main constituent and they occupy largest volume fraction

Diameter of a single fiber is about 10 microns

They may be continuous or discontinuous in length

TYPES OF GLASS FIBERTYPES OF GLASS FIBER E-Glass ndash E stands for electricalE-Glass ndash E stands for electrical S-Glass ndash S stands for high silica contentS-Glass ndash S stands for high silica content

High thermal expansion coefficientHigh thermal expansion coefficient High fatigue strengthHigh fatigue strength

C-Glass ndash C stands for CorrosionC-Glass ndash C stands for Corrosion Used in Chemical applicationsUsed in Chemical applications Storage tanksStorage tanks

R-Glass ndash R stands for RigidR-Glass ndash R stands for Rigid Structural applicationsStructural applications

D-Glass ndash D stands for DielectricD-Glass ndash D stands for Dielectric Low dielectric constantsLow dielectric constants

A-Glass ndash A Stands for appearanceA-Glass ndash A Stands for appearance To improve surface appearanceTo improve surface appearance For ornamental worksFor ornamental works

E-CR Glass ndash E-CR stands for Electrical and E-CR Glass ndash E-CR stands for Electrical and corrosion resistancecorrosion resistance

AR Glass ndash AR stands for Alkali resistanceAR Glass ndash AR stands for Alkali resistance

bull Critical fiber length for effective stiffening amp strengthening

fiber length15

fdc

fiber diameter

shear strength offiber-matrix interface

fiber strength in tension

Efficiency fiber lengthEfficiency fiber length

(x)

7

fiber length 15

fdc

Shorter thicker fiber

fiber length 15

fdc

(x)

Longer thinner fiber

Poorer fiber efficiency Better fiber efficiency

Why are Fibers of a Thin Diameter

1 Thinner fiber has higher ultimate strength because less chance

for inherent flaws Similar phenomenon in metals and alloys(Strength of a thin wire can be higher than its bulk material)

2 For the same volume of fibers thinner fibers has largersurface area thus has stronger bond with matrix (The totalsurface area of fibers is inversely proportional to the

diameterof fibers)

3 Thinner fiber has larger flexibility ( 1(EI)) and therefore isable to be bent without breaking (Woven fabric performs canbe made before impregnated with polymer matrix)

Composite Strength Longitudinal LoadingComposite Strength Longitudinal Loading

Continuous fibersContinuous fibers - - Estimate fiber-reinforced composite Estimate fiber-reinforced composite strength for long continuous fibers in a matrixstrength for long continuous fibers in a matrix

Longitudinal deformationLongitudinal deformation

cc = = mmVVmm + + ffVVff butbut cc = = mm = = ff volume fractionvolume fraction isostrainisostrain

Ec = Em Vm + EfVf longitudinal (extensional)

modulus

mm

ff

m

f

VE

VE

F

F f = fiber

m = matrixC-composite

Remembering E = and note this model corresponds to the ldquoupper boundrdquo for particulate composites

Matrix Matrix RResinsesins

- - The resin or The resin or polymerpolymer is the ldquogluerdquo that is the ldquogluerdquo that

holds the composite togetherholds the composite together

-The primary functions of the resin are to -The primary functions of the resin are to transfer stress between the reinforcing fiberstransfer stress between the reinforcing fibers

Examples Polyester Epoxy Vinyl Ester PolyurethaneExamples Polyester Epoxy Vinyl Ester Polyurethane

Transfer stresses between the fibers Provide a barrier against an adverse

environment Protect the surface of the fibers from

mechanical abrasion Determine inter-laminar shear strength Determine damage tolerance of composites Determine in-plane shear strength Determine the processibility of composites Determine heat resistance of composites

Role of Matrices in Composites

Role of MatrixRole of Matrix The primary roles of the matrix alloy then are to provideefficient transfer of load to the fibers and to blunt cracks inthe event that fiber failure occurs and so the matrix alloy forcontinuously reinforced composites may be chosen more fortoughness than for strength

On this basis lower strength more ductile and tougher matrix alloys may be utilized in continuously reinforced

composites

For discontinuously reinforced composites the matrix may govern composite strength-Then the choice of matrix will be influenced by consideration of the required composite strength and higher strength matrix alloys may be required

Functions of Matrix

Holds the fibres together Protects the fibres from environment

Distributes the loads evenly between fibres so that all fibres are subjected to the same amount of strain

Enhances transverse properties of a laminate Improves impact and fracture resistance of a component

Helps to avoid propagation of crack growth through the fibres by providing alternate failure path along the interface between the fibres and the matrix

Carry inter-laminar shear

Desired Properties of a Matrix

Reduced moisture absorption

Low shrinkage

Low coefficient of thermal expansion

Good flow characteristics so that it penetrates the fibre bundles completely and eliminates voids during the compactingcuring process

Must be elastic to transfer load to fibres

Desired Properties of a Matrix

Reasonable strength modulus and elongation (elongationshould be greater than fibre)

Strength at elevated temperature (depending on application)

Low temperature capability (depending on application)

Excellent chemical resistance (depending on application)

Should be easily processable into the final composite shape

Dimensional stability (maintains its shape)

FILLERSFILLERS

Control Compositesrsquo CostControl Compositesrsquo Cost Improved Mechanical PropertiesImproved Mechanical Properties Improved Chemical PropertiesImproved Chemical Properties Reduced Creep amp ShrinkageReduced Creep amp Shrinkage Low Tensile StrengthLow Tensile Strength Fire Retardant amp Chemical ResistantFire Retardant amp Chemical Resistant

TYPES OF FILLERTYPES OF FILLER Calcium CarbonateCalcium Carbonate KaolinKaolin Alumina TrihydrateAlumina Trihydrate Mica FeldsparMica Feldspar WollastoniteWollastonite Silica Talc GlassSilica Talc Glass

ADDITIVESADDITIVES

Improved Material PropertiesImproved Material Properties AestheticsAesthetics Enhanced WorkabilityEnhanced Workability Improved PerformanceImproved Performance

ADDITIVE TYPESADDITIVE TYPES

CatalystsCatalysts PromotersPromoters InhibitorsInhibitors Coloring DyesColoring Dyes Releasing AgentsReleasing Agents Antistatic AgentsAntistatic Agents Foaming AgentsFoaming Agents

Composites OfferComposites Offer High Strength to weight ratioHigh Strength to weight ratioHigh Stiffness to weight ratioHigh Stiffness to weight ratioHigh Modulus to weight ratioHigh Modulus to weight ratioLight WeightLight WeightDirectional strength Directional strength Corrosion resistance Corrosion resistance Weather resistance Weather resistance Dimensional stability Dimensional stability -low thermal conductivity -low thermal conductivity

-low -low coefficient of thermal expansioncoefficient of thermal expansion Radar transparencyRadar transparencyNon-magnetic Non-magnetic High impact strength High impact strength High High dielectricdielectric strength (insulator) strength (insulator) Low maintenance Low maintenance Long term durability Long term durability Part consolidation Part consolidation Small to large part geometry possible Small to large part geometry possible Tailored surface finish Tailored surface finish Design FlexibilityDesign Flexibility

Property comparisonProperty comparison

Material

Tensile modulus

(E) ( 2 mGN )

Tensile strength( u )

( 2 mGN )

Density ( )

( 3 cmg )

Specific modulus

( E )

Specific strength ( u )

E-Glass 724 53 254 285 138

Graphite 3900 21 190 2050 11

Boron 3850 28 263 1460 11

Kevlar ndash 49 130 28 150 87 187

Steel 210 034 ndash 21 78 269 0043 ndash

027

Aluminum alloys

70 014 ndash 062 27 259 0052 ndash

023

CompositeComposite strengthstrength depends on the following depends on the following factorsfactors

Inherent fiber Inherent fiber strength Fiber length strength Fiber length Number of flawsNumber of flaws

Fiber shape Fiber shape The bonding of the The bonding of the

fiber (equally stress fiber (equally stress distribution)distribution)

Voids Voids Moisture (coupling Moisture (coupling

agents)agents)

Classification of Composite MaterialsClassification of Composite Materials

11 Traditional compositesTraditional composites ndash composite materials ndash composite materials that occur in nature or have been produced by that occur in nature or have been produced by civilizations for many years civilizations for many years ExamplesExamples wood wood (cellulose fibers in lignin

matrix) concrete asphalt concrete asphalt

22 Synthetic compositesSynthetic composites - modern material - modern material systems normally associated with the systems normally associated with the manufacturing industries in which the manufacturing industries in which the components are first produced separately and components are first produced separately and then combined in a controlled way to achieve then combined in a controlled way to achieve the desired structure properties and part the desired structure properties and part geometry geometry

Classification of Classification of SyntheticSynthetic Composites Composites Based on MatrixBased on Matrix

Matrix

Reinforcement

Metal Ceramic Polymer

Metal Powder metallurgy parts ndash combining immiscible metals

Cermets (ceramic-metal composite)

Brake pads

Ceramic Cermets TiC TiCNCemented carbides ndash used in toolsFiber-reinforced metals

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer Kevlar fibers in an epoxy matrix

Elemental (Carbon Boron etc)

Fiber reinforced metalsAuto partsaerospace

Rubber with carbon (tires)Boron Carbon reinforced plastics

MMCrsquos CMCrsquos PMCrsquosMetal Matrix Composites Ceramic Matrix Comprsquos Polymer Matrix Comprsquos

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 5: Introduction and Classification of Composites

Micro mechanics Macro mechanics

Major ConstituentsMajor Constituents

FiberMatrixFillersCoupling agentsColorants

FIBERSFIBERS

Principle Load carrying member

Main constituent and they occupy largest volume fraction

Diameter of a single fiber is about 10 microns

They may be continuous or discontinuous in length

TYPES OF GLASS FIBERTYPES OF GLASS FIBER E-Glass ndash E stands for electricalE-Glass ndash E stands for electrical S-Glass ndash S stands for high silica contentS-Glass ndash S stands for high silica content

High thermal expansion coefficientHigh thermal expansion coefficient High fatigue strengthHigh fatigue strength

C-Glass ndash C stands for CorrosionC-Glass ndash C stands for Corrosion Used in Chemical applicationsUsed in Chemical applications Storage tanksStorage tanks

R-Glass ndash R stands for RigidR-Glass ndash R stands for Rigid Structural applicationsStructural applications

D-Glass ndash D stands for DielectricD-Glass ndash D stands for Dielectric Low dielectric constantsLow dielectric constants

A-Glass ndash A Stands for appearanceA-Glass ndash A Stands for appearance To improve surface appearanceTo improve surface appearance For ornamental worksFor ornamental works

E-CR Glass ndash E-CR stands for Electrical and E-CR Glass ndash E-CR stands for Electrical and corrosion resistancecorrosion resistance

AR Glass ndash AR stands for Alkali resistanceAR Glass ndash AR stands for Alkali resistance

bull Critical fiber length for effective stiffening amp strengthening

fiber length15

fdc

fiber diameter

shear strength offiber-matrix interface

fiber strength in tension

Efficiency fiber lengthEfficiency fiber length

(x)

7

fiber length 15

fdc

Shorter thicker fiber

fiber length 15

fdc

(x)

Longer thinner fiber

Poorer fiber efficiency Better fiber efficiency

Why are Fibers of a Thin Diameter

1 Thinner fiber has higher ultimate strength because less chance

for inherent flaws Similar phenomenon in metals and alloys(Strength of a thin wire can be higher than its bulk material)

2 For the same volume of fibers thinner fibers has largersurface area thus has stronger bond with matrix (The totalsurface area of fibers is inversely proportional to the

diameterof fibers)

3 Thinner fiber has larger flexibility ( 1(EI)) and therefore isable to be bent without breaking (Woven fabric performs canbe made before impregnated with polymer matrix)

Composite Strength Longitudinal LoadingComposite Strength Longitudinal Loading

Continuous fibersContinuous fibers - - Estimate fiber-reinforced composite Estimate fiber-reinforced composite strength for long continuous fibers in a matrixstrength for long continuous fibers in a matrix

Longitudinal deformationLongitudinal deformation

cc = = mmVVmm + + ffVVff butbut cc = = mm = = ff volume fractionvolume fraction isostrainisostrain

Ec = Em Vm + EfVf longitudinal (extensional)

modulus

mm

ff

m

f

VE

VE

F

F f = fiber

m = matrixC-composite

Remembering E = and note this model corresponds to the ldquoupper boundrdquo for particulate composites

Matrix Matrix RResinsesins

- - The resin or The resin or polymerpolymer is the ldquogluerdquo that is the ldquogluerdquo that

holds the composite togetherholds the composite together

-The primary functions of the resin are to -The primary functions of the resin are to transfer stress between the reinforcing fiberstransfer stress between the reinforcing fibers

Examples Polyester Epoxy Vinyl Ester PolyurethaneExamples Polyester Epoxy Vinyl Ester Polyurethane

Transfer stresses between the fibers Provide a barrier against an adverse

environment Protect the surface of the fibers from

mechanical abrasion Determine inter-laminar shear strength Determine damage tolerance of composites Determine in-plane shear strength Determine the processibility of composites Determine heat resistance of composites

Role of Matrices in Composites

Role of MatrixRole of Matrix The primary roles of the matrix alloy then are to provideefficient transfer of load to the fibers and to blunt cracks inthe event that fiber failure occurs and so the matrix alloy forcontinuously reinforced composites may be chosen more fortoughness than for strength

On this basis lower strength more ductile and tougher matrix alloys may be utilized in continuously reinforced

composites

For discontinuously reinforced composites the matrix may govern composite strength-Then the choice of matrix will be influenced by consideration of the required composite strength and higher strength matrix alloys may be required

Functions of Matrix

Holds the fibres together Protects the fibres from environment

Distributes the loads evenly between fibres so that all fibres are subjected to the same amount of strain

Enhances transverse properties of a laminate Improves impact and fracture resistance of a component

Helps to avoid propagation of crack growth through the fibres by providing alternate failure path along the interface between the fibres and the matrix

Carry inter-laminar shear

Desired Properties of a Matrix

Reduced moisture absorption

Low shrinkage

Low coefficient of thermal expansion

Good flow characteristics so that it penetrates the fibre bundles completely and eliminates voids during the compactingcuring process

Must be elastic to transfer load to fibres

Desired Properties of a Matrix

Reasonable strength modulus and elongation (elongationshould be greater than fibre)

Strength at elevated temperature (depending on application)

Low temperature capability (depending on application)

Excellent chemical resistance (depending on application)

Should be easily processable into the final composite shape

Dimensional stability (maintains its shape)

FILLERSFILLERS

Control Compositesrsquo CostControl Compositesrsquo Cost Improved Mechanical PropertiesImproved Mechanical Properties Improved Chemical PropertiesImproved Chemical Properties Reduced Creep amp ShrinkageReduced Creep amp Shrinkage Low Tensile StrengthLow Tensile Strength Fire Retardant amp Chemical ResistantFire Retardant amp Chemical Resistant

TYPES OF FILLERTYPES OF FILLER Calcium CarbonateCalcium Carbonate KaolinKaolin Alumina TrihydrateAlumina Trihydrate Mica FeldsparMica Feldspar WollastoniteWollastonite Silica Talc GlassSilica Talc Glass

ADDITIVESADDITIVES

Improved Material PropertiesImproved Material Properties AestheticsAesthetics Enhanced WorkabilityEnhanced Workability Improved PerformanceImproved Performance

ADDITIVE TYPESADDITIVE TYPES

CatalystsCatalysts PromotersPromoters InhibitorsInhibitors Coloring DyesColoring Dyes Releasing AgentsReleasing Agents Antistatic AgentsAntistatic Agents Foaming AgentsFoaming Agents

Composites OfferComposites Offer High Strength to weight ratioHigh Strength to weight ratioHigh Stiffness to weight ratioHigh Stiffness to weight ratioHigh Modulus to weight ratioHigh Modulus to weight ratioLight WeightLight WeightDirectional strength Directional strength Corrosion resistance Corrosion resistance Weather resistance Weather resistance Dimensional stability Dimensional stability -low thermal conductivity -low thermal conductivity

-low -low coefficient of thermal expansioncoefficient of thermal expansion Radar transparencyRadar transparencyNon-magnetic Non-magnetic High impact strength High impact strength High High dielectricdielectric strength (insulator) strength (insulator) Low maintenance Low maintenance Long term durability Long term durability Part consolidation Part consolidation Small to large part geometry possible Small to large part geometry possible Tailored surface finish Tailored surface finish Design FlexibilityDesign Flexibility

Property comparisonProperty comparison

Material

Tensile modulus

(E) ( 2 mGN )

Tensile strength( u )

( 2 mGN )

Density ( )

( 3 cmg )

Specific modulus

( E )

Specific strength ( u )

E-Glass 724 53 254 285 138

Graphite 3900 21 190 2050 11

Boron 3850 28 263 1460 11

Kevlar ndash 49 130 28 150 87 187

Steel 210 034 ndash 21 78 269 0043 ndash

027

Aluminum alloys

70 014 ndash 062 27 259 0052 ndash

023

CompositeComposite strengthstrength depends on the following depends on the following factorsfactors

Inherent fiber Inherent fiber strength Fiber length strength Fiber length Number of flawsNumber of flaws

Fiber shape Fiber shape The bonding of the The bonding of the

fiber (equally stress fiber (equally stress distribution)distribution)

Voids Voids Moisture (coupling Moisture (coupling

agents)agents)

Classification of Composite MaterialsClassification of Composite Materials

11 Traditional compositesTraditional composites ndash composite materials ndash composite materials that occur in nature or have been produced by that occur in nature or have been produced by civilizations for many years civilizations for many years ExamplesExamples wood wood (cellulose fibers in lignin

matrix) concrete asphalt concrete asphalt

22 Synthetic compositesSynthetic composites - modern material - modern material systems normally associated with the systems normally associated with the manufacturing industries in which the manufacturing industries in which the components are first produced separately and components are first produced separately and then combined in a controlled way to achieve then combined in a controlled way to achieve the desired structure properties and part the desired structure properties and part geometry geometry

Classification of Classification of SyntheticSynthetic Composites Composites Based on MatrixBased on Matrix

Matrix

Reinforcement

Metal Ceramic Polymer

Metal Powder metallurgy parts ndash combining immiscible metals

Cermets (ceramic-metal composite)

Brake pads

Ceramic Cermets TiC TiCNCemented carbides ndash used in toolsFiber-reinforced metals

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer Kevlar fibers in an epoxy matrix

Elemental (Carbon Boron etc)

Fiber reinforced metalsAuto partsaerospace

Rubber with carbon (tires)Boron Carbon reinforced plastics

MMCrsquos CMCrsquos PMCrsquosMetal Matrix Composites Ceramic Matrix Comprsquos Polymer Matrix Comprsquos

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 6: Introduction and Classification of Composites

Major ConstituentsMajor Constituents

FiberMatrixFillersCoupling agentsColorants

FIBERSFIBERS

Principle Load carrying member

Main constituent and they occupy largest volume fraction

Diameter of a single fiber is about 10 microns

They may be continuous or discontinuous in length

TYPES OF GLASS FIBERTYPES OF GLASS FIBER E-Glass ndash E stands for electricalE-Glass ndash E stands for electrical S-Glass ndash S stands for high silica contentS-Glass ndash S stands for high silica content

High thermal expansion coefficientHigh thermal expansion coefficient High fatigue strengthHigh fatigue strength

C-Glass ndash C stands for CorrosionC-Glass ndash C stands for Corrosion Used in Chemical applicationsUsed in Chemical applications Storage tanksStorage tanks

R-Glass ndash R stands for RigidR-Glass ndash R stands for Rigid Structural applicationsStructural applications

D-Glass ndash D stands for DielectricD-Glass ndash D stands for Dielectric Low dielectric constantsLow dielectric constants

A-Glass ndash A Stands for appearanceA-Glass ndash A Stands for appearance To improve surface appearanceTo improve surface appearance For ornamental worksFor ornamental works

E-CR Glass ndash E-CR stands for Electrical and E-CR Glass ndash E-CR stands for Electrical and corrosion resistancecorrosion resistance

AR Glass ndash AR stands for Alkali resistanceAR Glass ndash AR stands for Alkali resistance

bull Critical fiber length for effective stiffening amp strengthening

fiber length15

fdc

fiber diameter

shear strength offiber-matrix interface

fiber strength in tension

Efficiency fiber lengthEfficiency fiber length

(x)

7

fiber length 15

fdc

Shorter thicker fiber

fiber length 15

fdc

(x)

Longer thinner fiber

Poorer fiber efficiency Better fiber efficiency

Why are Fibers of a Thin Diameter

1 Thinner fiber has higher ultimate strength because less chance

for inherent flaws Similar phenomenon in metals and alloys(Strength of a thin wire can be higher than its bulk material)

2 For the same volume of fibers thinner fibers has largersurface area thus has stronger bond with matrix (The totalsurface area of fibers is inversely proportional to the

diameterof fibers)

3 Thinner fiber has larger flexibility ( 1(EI)) and therefore isable to be bent without breaking (Woven fabric performs canbe made before impregnated with polymer matrix)

Composite Strength Longitudinal LoadingComposite Strength Longitudinal Loading

Continuous fibersContinuous fibers - - Estimate fiber-reinforced composite Estimate fiber-reinforced composite strength for long continuous fibers in a matrixstrength for long continuous fibers in a matrix

Longitudinal deformationLongitudinal deformation

cc = = mmVVmm + + ffVVff butbut cc = = mm = = ff volume fractionvolume fraction isostrainisostrain

Ec = Em Vm + EfVf longitudinal (extensional)

modulus

mm

ff

m

f

VE

VE

F

F f = fiber

m = matrixC-composite

Remembering E = and note this model corresponds to the ldquoupper boundrdquo for particulate composites

Matrix Matrix RResinsesins

- - The resin or The resin or polymerpolymer is the ldquogluerdquo that is the ldquogluerdquo that

holds the composite togetherholds the composite together

-The primary functions of the resin are to -The primary functions of the resin are to transfer stress between the reinforcing fiberstransfer stress between the reinforcing fibers

Examples Polyester Epoxy Vinyl Ester PolyurethaneExamples Polyester Epoxy Vinyl Ester Polyurethane

Transfer stresses between the fibers Provide a barrier against an adverse

environment Protect the surface of the fibers from

mechanical abrasion Determine inter-laminar shear strength Determine damage tolerance of composites Determine in-plane shear strength Determine the processibility of composites Determine heat resistance of composites

Role of Matrices in Composites

Role of MatrixRole of Matrix The primary roles of the matrix alloy then are to provideefficient transfer of load to the fibers and to blunt cracks inthe event that fiber failure occurs and so the matrix alloy forcontinuously reinforced composites may be chosen more fortoughness than for strength

On this basis lower strength more ductile and tougher matrix alloys may be utilized in continuously reinforced

composites

For discontinuously reinforced composites the matrix may govern composite strength-Then the choice of matrix will be influenced by consideration of the required composite strength and higher strength matrix alloys may be required

Functions of Matrix

Holds the fibres together Protects the fibres from environment

Distributes the loads evenly between fibres so that all fibres are subjected to the same amount of strain

Enhances transverse properties of a laminate Improves impact and fracture resistance of a component

Helps to avoid propagation of crack growth through the fibres by providing alternate failure path along the interface between the fibres and the matrix

Carry inter-laminar shear

Desired Properties of a Matrix

Reduced moisture absorption

Low shrinkage

Low coefficient of thermal expansion

Good flow characteristics so that it penetrates the fibre bundles completely and eliminates voids during the compactingcuring process

Must be elastic to transfer load to fibres

Desired Properties of a Matrix

Reasonable strength modulus and elongation (elongationshould be greater than fibre)

Strength at elevated temperature (depending on application)

Low temperature capability (depending on application)

Excellent chemical resistance (depending on application)

Should be easily processable into the final composite shape

Dimensional stability (maintains its shape)

FILLERSFILLERS

Control Compositesrsquo CostControl Compositesrsquo Cost Improved Mechanical PropertiesImproved Mechanical Properties Improved Chemical PropertiesImproved Chemical Properties Reduced Creep amp ShrinkageReduced Creep amp Shrinkage Low Tensile StrengthLow Tensile Strength Fire Retardant amp Chemical ResistantFire Retardant amp Chemical Resistant

TYPES OF FILLERTYPES OF FILLER Calcium CarbonateCalcium Carbonate KaolinKaolin Alumina TrihydrateAlumina Trihydrate Mica FeldsparMica Feldspar WollastoniteWollastonite Silica Talc GlassSilica Talc Glass

ADDITIVESADDITIVES

Improved Material PropertiesImproved Material Properties AestheticsAesthetics Enhanced WorkabilityEnhanced Workability Improved PerformanceImproved Performance

ADDITIVE TYPESADDITIVE TYPES

CatalystsCatalysts PromotersPromoters InhibitorsInhibitors Coloring DyesColoring Dyes Releasing AgentsReleasing Agents Antistatic AgentsAntistatic Agents Foaming AgentsFoaming Agents

Composites OfferComposites Offer High Strength to weight ratioHigh Strength to weight ratioHigh Stiffness to weight ratioHigh Stiffness to weight ratioHigh Modulus to weight ratioHigh Modulus to weight ratioLight WeightLight WeightDirectional strength Directional strength Corrosion resistance Corrosion resistance Weather resistance Weather resistance Dimensional stability Dimensional stability -low thermal conductivity -low thermal conductivity

-low -low coefficient of thermal expansioncoefficient of thermal expansion Radar transparencyRadar transparencyNon-magnetic Non-magnetic High impact strength High impact strength High High dielectricdielectric strength (insulator) strength (insulator) Low maintenance Low maintenance Long term durability Long term durability Part consolidation Part consolidation Small to large part geometry possible Small to large part geometry possible Tailored surface finish Tailored surface finish Design FlexibilityDesign Flexibility

Property comparisonProperty comparison

Material

Tensile modulus

(E) ( 2 mGN )

Tensile strength( u )

( 2 mGN )

Density ( )

( 3 cmg )

Specific modulus

( E )

Specific strength ( u )

E-Glass 724 53 254 285 138

Graphite 3900 21 190 2050 11

Boron 3850 28 263 1460 11

Kevlar ndash 49 130 28 150 87 187

Steel 210 034 ndash 21 78 269 0043 ndash

027

Aluminum alloys

70 014 ndash 062 27 259 0052 ndash

023

CompositeComposite strengthstrength depends on the following depends on the following factorsfactors

Inherent fiber Inherent fiber strength Fiber length strength Fiber length Number of flawsNumber of flaws

Fiber shape Fiber shape The bonding of the The bonding of the

fiber (equally stress fiber (equally stress distribution)distribution)

Voids Voids Moisture (coupling Moisture (coupling

agents)agents)

Classification of Composite MaterialsClassification of Composite Materials

11 Traditional compositesTraditional composites ndash composite materials ndash composite materials that occur in nature or have been produced by that occur in nature or have been produced by civilizations for many years civilizations for many years ExamplesExamples wood wood (cellulose fibers in lignin

matrix) concrete asphalt concrete asphalt

22 Synthetic compositesSynthetic composites - modern material - modern material systems normally associated with the systems normally associated with the manufacturing industries in which the manufacturing industries in which the components are first produced separately and components are first produced separately and then combined in a controlled way to achieve then combined in a controlled way to achieve the desired structure properties and part the desired structure properties and part geometry geometry

Classification of Classification of SyntheticSynthetic Composites Composites Based on MatrixBased on Matrix

Matrix

Reinforcement

Metal Ceramic Polymer

Metal Powder metallurgy parts ndash combining immiscible metals

Cermets (ceramic-metal composite)

Brake pads

Ceramic Cermets TiC TiCNCemented carbides ndash used in toolsFiber-reinforced metals

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer Kevlar fibers in an epoxy matrix

Elemental (Carbon Boron etc)

Fiber reinforced metalsAuto partsaerospace

Rubber with carbon (tires)Boron Carbon reinforced plastics

MMCrsquos CMCrsquos PMCrsquosMetal Matrix Composites Ceramic Matrix Comprsquos Polymer Matrix Comprsquos

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 7: Introduction and Classification of Composites

FIBERSFIBERS

Principle Load carrying member

Main constituent and they occupy largest volume fraction

Diameter of a single fiber is about 10 microns

They may be continuous or discontinuous in length

TYPES OF GLASS FIBERTYPES OF GLASS FIBER E-Glass ndash E stands for electricalE-Glass ndash E stands for electrical S-Glass ndash S stands for high silica contentS-Glass ndash S stands for high silica content

High thermal expansion coefficientHigh thermal expansion coefficient High fatigue strengthHigh fatigue strength

C-Glass ndash C stands for CorrosionC-Glass ndash C stands for Corrosion Used in Chemical applicationsUsed in Chemical applications Storage tanksStorage tanks

R-Glass ndash R stands for RigidR-Glass ndash R stands for Rigid Structural applicationsStructural applications

D-Glass ndash D stands for DielectricD-Glass ndash D stands for Dielectric Low dielectric constantsLow dielectric constants

A-Glass ndash A Stands for appearanceA-Glass ndash A Stands for appearance To improve surface appearanceTo improve surface appearance For ornamental worksFor ornamental works

E-CR Glass ndash E-CR stands for Electrical and E-CR Glass ndash E-CR stands for Electrical and corrosion resistancecorrosion resistance

AR Glass ndash AR stands for Alkali resistanceAR Glass ndash AR stands for Alkali resistance

bull Critical fiber length for effective stiffening amp strengthening

fiber length15

fdc

fiber diameter

shear strength offiber-matrix interface

fiber strength in tension

Efficiency fiber lengthEfficiency fiber length

(x)

7

fiber length 15

fdc

Shorter thicker fiber

fiber length 15

fdc

(x)

Longer thinner fiber

Poorer fiber efficiency Better fiber efficiency

Why are Fibers of a Thin Diameter

1 Thinner fiber has higher ultimate strength because less chance

for inherent flaws Similar phenomenon in metals and alloys(Strength of a thin wire can be higher than its bulk material)

2 For the same volume of fibers thinner fibers has largersurface area thus has stronger bond with matrix (The totalsurface area of fibers is inversely proportional to the

diameterof fibers)

3 Thinner fiber has larger flexibility ( 1(EI)) and therefore isable to be bent without breaking (Woven fabric performs canbe made before impregnated with polymer matrix)

Composite Strength Longitudinal LoadingComposite Strength Longitudinal Loading

Continuous fibersContinuous fibers - - Estimate fiber-reinforced composite Estimate fiber-reinforced composite strength for long continuous fibers in a matrixstrength for long continuous fibers in a matrix

Longitudinal deformationLongitudinal deformation

cc = = mmVVmm + + ffVVff butbut cc = = mm = = ff volume fractionvolume fraction isostrainisostrain

Ec = Em Vm + EfVf longitudinal (extensional)

modulus

mm

ff

m

f

VE

VE

F

F f = fiber

m = matrixC-composite

Remembering E = and note this model corresponds to the ldquoupper boundrdquo for particulate composites

Matrix Matrix RResinsesins

- - The resin or The resin or polymerpolymer is the ldquogluerdquo that is the ldquogluerdquo that

holds the composite togetherholds the composite together

-The primary functions of the resin are to -The primary functions of the resin are to transfer stress between the reinforcing fiberstransfer stress between the reinforcing fibers

Examples Polyester Epoxy Vinyl Ester PolyurethaneExamples Polyester Epoxy Vinyl Ester Polyurethane

Transfer stresses between the fibers Provide a barrier against an adverse

environment Protect the surface of the fibers from

mechanical abrasion Determine inter-laminar shear strength Determine damage tolerance of composites Determine in-plane shear strength Determine the processibility of composites Determine heat resistance of composites

Role of Matrices in Composites

Role of MatrixRole of Matrix The primary roles of the matrix alloy then are to provideefficient transfer of load to the fibers and to blunt cracks inthe event that fiber failure occurs and so the matrix alloy forcontinuously reinforced composites may be chosen more fortoughness than for strength

On this basis lower strength more ductile and tougher matrix alloys may be utilized in continuously reinforced

composites

For discontinuously reinforced composites the matrix may govern composite strength-Then the choice of matrix will be influenced by consideration of the required composite strength and higher strength matrix alloys may be required

Functions of Matrix

Holds the fibres together Protects the fibres from environment

Distributes the loads evenly between fibres so that all fibres are subjected to the same amount of strain

Enhances transverse properties of a laminate Improves impact and fracture resistance of a component

Helps to avoid propagation of crack growth through the fibres by providing alternate failure path along the interface between the fibres and the matrix

Carry inter-laminar shear

Desired Properties of a Matrix

Reduced moisture absorption

Low shrinkage

Low coefficient of thermal expansion

Good flow characteristics so that it penetrates the fibre bundles completely and eliminates voids during the compactingcuring process

Must be elastic to transfer load to fibres

Desired Properties of a Matrix

Reasonable strength modulus and elongation (elongationshould be greater than fibre)

Strength at elevated temperature (depending on application)

Low temperature capability (depending on application)

Excellent chemical resistance (depending on application)

Should be easily processable into the final composite shape

Dimensional stability (maintains its shape)

FILLERSFILLERS

Control Compositesrsquo CostControl Compositesrsquo Cost Improved Mechanical PropertiesImproved Mechanical Properties Improved Chemical PropertiesImproved Chemical Properties Reduced Creep amp ShrinkageReduced Creep amp Shrinkage Low Tensile StrengthLow Tensile Strength Fire Retardant amp Chemical ResistantFire Retardant amp Chemical Resistant

TYPES OF FILLERTYPES OF FILLER Calcium CarbonateCalcium Carbonate KaolinKaolin Alumina TrihydrateAlumina Trihydrate Mica FeldsparMica Feldspar WollastoniteWollastonite Silica Talc GlassSilica Talc Glass

ADDITIVESADDITIVES

Improved Material PropertiesImproved Material Properties AestheticsAesthetics Enhanced WorkabilityEnhanced Workability Improved PerformanceImproved Performance

ADDITIVE TYPESADDITIVE TYPES

CatalystsCatalysts PromotersPromoters InhibitorsInhibitors Coloring DyesColoring Dyes Releasing AgentsReleasing Agents Antistatic AgentsAntistatic Agents Foaming AgentsFoaming Agents

Composites OfferComposites Offer High Strength to weight ratioHigh Strength to weight ratioHigh Stiffness to weight ratioHigh Stiffness to weight ratioHigh Modulus to weight ratioHigh Modulus to weight ratioLight WeightLight WeightDirectional strength Directional strength Corrosion resistance Corrosion resistance Weather resistance Weather resistance Dimensional stability Dimensional stability -low thermal conductivity -low thermal conductivity

-low -low coefficient of thermal expansioncoefficient of thermal expansion Radar transparencyRadar transparencyNon-magnetic Non-magnetic High impact strength High impact strength High High dielectricdielectric strength (insulator) strength (insulator) Low maintenance Low maintenance Long term durability Long term durability Part consolidation Part consolidation Small to large part geometry possible Small to large part geometry possible Tailored surface finish Tailored surface finish Design FlexibilityDesign Flexibility

Property comparisonProperty comparison

Material

Tensile modulus

(E) ( 2 mGN )

Tensile strength( u )

( 2 mGN )

Density ( )

( 3 cmg )

Specific modulus

( E )

Specific strength ( u )

E-Glass 724 53 254 285 138

Graphite 3900 21 190 2050 11

Boron 3850 28 263 1460 11

Kevlar ndash 49 130 28 150 87 187

Steel 210 034 ndash 21 78 269 0043 ndash

027

Aluminum alloys

70 014 ndash 062 27 259 0052 ndash

023

CompositeComposite strengthstrength depends on the following depends on the following factorsfactors

Inherent fiber Inherent fiber strength Fiber length strength Fiber length Number of flawsNumber of flaws

Fiber shape Fiber shape The bonding of the The bonding of the

fiber (equally stress fiber (equally stress distribution)distribution)

Voids Voids Moisture (coupling Moisture (coupling

agents)agents)

Classification of Composite MaterialsClassification of Composite Materials

11 Traditional compositesTraditional composites ndash composite materials ndash composite materials that occur in nature or have been produced by that occur in nature or have been produced by civilizations for many years civilizations for many years ExamplesExamples wood wood (cellulose fibers in lignin

matrix) concrete asphalt concrete asphalt

22 Synthetic compositesSynthetic composites - modern material - modern material systems normally associated with the systems normally associated with the manufacturing industries in which the manufacturing industries in which the components are first produced separately and components are first produced separately and then combined in a controlled way to achieve then combined in a controlled way to achieve the desired structure properties and part the desired structure properties and part geometry geometry

Classification of Classification of SyntheticSynthetic Composites Composites Based on MatrixBased on Matrix

Matrix

Reinforcement

Metal Ceramic Polymer

Metal Powder metallurgy parts ndash combining immiscible metals

Cermets (ceramic-metal composite)

Brake pads

Ceramic Cermets TiC TiCNCemented carbides ndash used in toolsFiber-reinforced metals

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer Kevlar fibers in an epoxy matrix

Elemental (Carbon Boron etc)

Fiber reinforced metalsAuto partsaerospace

Rubber with carbon (tires)Boron Carbon reinforced plastics

MMCrsquos CMCrsquos PMCrsquosMetal Matrix Composites Ceramic Matrix Comprsquos Polymer Matrix Comprsquos

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 8: Introduction and Classification of Composites

TYPES OF GLASS FIBERTYPES OF GLASS FIBER E-Glass ndash E stands for electricalE-Glass ndash E stands for electrical S-Glass ndash S stands for high silica contentS-Glass ndash S stands for high silica content

High thermal expansion coefficientHigh thermal expansion coefficient High fatigue strengthHigh fatigue strength

C-Glass ndash C stands for CorrosionC-Glass ndash C stands for Corrosion Used in Chemical applicationsUsed in Chemical applications Storage tanksStorage tanks

R-Glass ndash R stands for RigidR-Glass ndash R stands for Rigid Structural applicationsStructural applications

D-Glass ndash D stands for DielectricD-Glass ndash D stands for Dielectric Low dielectric constantsLow dielectric constants

A-Glass ndash A Stands for appearanceA-Glass ndash A Stands for appearance To improve surface appearanceTo improve surface appearance For ornamental worksFor ornamental works

E-CR Glass ndash E-CR stands for Electrical and E-CR Glass ndash E-CR stands for Electrical and corrosion resistancecorrosion resistance

AR Glass ndash AR stands for Alkali resistanceAR Glass ndash AR stands for Alkali resistance

bull Critical fiber length for effective stiffening amp strengthening

fiber length15

fdc

fiber diameter

shear strength offiber-matrix interface

fiber strength in tension

Efficiency fiber lengthEfficiency fiber length

(x)

7

fiber length 15

fdc

Shorter thicker fiber

fiber length 15

fdc

(x)

Longer thinner fiber

Poorer fiber efficiency Better fiber efficiency

Why are Fibers of a Thin Diameter

1 Thinner fiber has higher ultimate strength because less chance

for inherent flaws Similar phenomenon in metals and alloys(Strength of a thin wire can be higher than its bulk material)

2 For the same volume of fibers thinner fibers has largersurface area thus has stronger bond with matrix (The totalsurface area of fibers is inversely proportional to the

diameterof fibers)

3 Thinner fiber has larger flexibility ( 1(EI)) and therefore isable to be bent without breaking (Woven fabric performs canbe made before impregnated with polymer matrix)

Composite Strength Longitudinal LoadingComposite Strength Longitudinal Loading

Continuous fibersContinuous fibers - - Estimate fiber-reinforced composite Estimate fiber-reinforced composite strength for long continuous fibers in a matrixstrength for long continuous fibers in a matrix

Longitudinal deformationLongitudinal deformation

cc = = mmVVmm + + ffVVff butbut cc = = mm = = ff volume fractionvolume fraction isostrainisostrain

Ec = Em Vm + EfVf longitudinal (extensional)

modulus

mm

ff

m

f

VE

VE

F

F f = fiber

m = matrixC-composite

Remembering E = and note this model corresponds to the ldquoupper boundrdquo for particulate composites

Matrix Matrix RResinsesins

- - The resin or The resin or polymerpolymer is the ldquogluerdquo that is the ldquogluerdquo that

holds the composite togetherholds the composite together

-The primary functions of the resin are to -The primary functions of the resin are to transfer stress between the reinforcing fiberstransfer stress between the reinforcing fibers

Examples Polyester Epoxy Vinyl Ester PolyurethaneExamples Polyester Epoxy Vinyl Ester Polyurethane

Transfer stresses between the fibers Provide a barrier against an adverse

environment Protect the surface of the fibers from

mechanical abrasion Determine inter-laminar shear strength Determine damage tolerance of composites Determine in-plane shear strength Determine the processibility of composites Determine heat resistance of composites

Role of Matrices in Composites

Role of MatrixRole of Matrix The primary roles of the matrix alloy then are to provideefficient transfer of load to the fibers and to blunt cracks inthe event that fiber failure occurs and so the matrix alloy forcontinuously reinforced composites may be chosen more fortoughness than for strength

On this basis lower strength more ductile and tougher matrix alloys may be utilized in continuously reinforced

composites

For discontinuously reinforced composites the matrix may govern composite strength-Then the choice of matrix will be influenced by consideration of the required composite strength and higher strength matrix alloys may be required

Functions of Matrix

Holds the fibres together Protects the fibres from environment

Distributes the loads evenly between fibres so that all fibres are subjected to the same amount of strain

Enhances transverse properties of a laminate Improves impact and fracture resistance of a component

Helps to avoid propagation of crack growth through the fibres by providing alternate failure path along the interface between the fibres and the matrix

Carry inter-laminar shear

Desired Properties of a Matrix

Reduced moisture absorption

Low shrinkage

Low coefficient of thermal expansion

Good flow characteristics so that it penetrates the fibre bundles completely and eliminates voids during the compactingcuring process

Must be elastic to transfer load to fibres

Desired Properties of a Matrix

Reasonable strength modulus and elongation (elongationshould be greater than fibre)

Strength at elevated temperature (depending on application)

Low temperature capability (depending on application)

Excellent chemical resistance (depending on application)

Should be easily processable into the final composite shape

Dimensional stability (maintains its shape)

FILLERSFILLERS

Control Compositesrsquo CostControl Compositesrsquo Cost Improved Mechanical PropertiesImproved Mechanical Properties Improved Chemical PropertiesImproved Chemical Properties Reduced Creep amp ShrinkageReduced Creep amp Shrinkage Low Tensile StrengthLow Tensile Strength Fire Retardant amp Chemical ResistantFire Retardant amp Chemical Resistant

TYPES OF FILLERTYPES OF FILLER Calcium CarbonateCalcium Carbonate KaolinKaolin Alumina TrihydrateAlumina Trihydrate Mica FeldsparMica Feldspar WollastoniteWollastonite Silica Talc GlassSilica Talc Glass

ADDITIVESADDITIVES

Improved Material PropertiesImproved Material Properties AestheticsAesthetics Enhanced WorkabilityEnhanced Workability Improved PerformanceImproved Performance

ADDITIVE TYPESADDITIVE TYPES

CatalystsCatalysts PromotersPromoters InhibitorsInhibitors Coloring DyesColoring Dyes Releasing AgentsReleasing Agents Antistatic AgentsAntistatic Agents Foaming AgentsFoaming Agents

Composites OfferComposites Offer High Strength to weight ratioHigh Strength to weight ratioHigh Stiffness to weight ratioHigh Stiffness to weight ratioHigh Modulus to weight ratioHigh Modulus to weight ratioLight WeightLight WeightDirectional strength Directional strength Corrosion resistance Corrosion resistance Weather resistance Weather resistance Dimensional stability Dimensional stability -low thermal conductivity -low thermal conductivity

-low -low coefficient of thermal expansioncoefficient of thermal expansion Radar transparencyRadar transparencyNon-magnetic Non-magnetic High impact strength High impact strength High High dielectricdielectric strength (insulator) strength (insulator) Low maintenance Low maintenance Long term durability Long term durability Part consolidation Part consolidation Small to large part geometry possible Small to large part geometry possible Tailored surface finish Tailored surface finish Design FlexibilityDesign Flexibility

Property comparisonProperty comparison

Material

Tensile modulus

(E) ( 2 mGN )

Tensile strength( u )

( 2 mGN )

Density ( )

( 3 cmg )

Specific modulus

( E )

Specific strength ( u )

E-Glass 724 53 254 285 138

Graphite 3900 21 190 2050 11

Boron 3850 28 263 1460 11

Kevlar ndash 49 130 28 150 87 187

Steel 210 034 ndash 21 78 269 0043 ndash

027

Aluminum alloys

70 014 ndash 062 27 259 0052 ndash

023

CompositeComposite strengthstrength depends on the following depends on the following factorsfactors

Inherent fiber Inherent fiber strength Fiber length strength Fiber length Number of flawsNumber of flaws

Fiber shape Fiber shape The bonding of the The bonding of the

fiber (equally stress fiber (equally stress distribution)distribution)

Voids Voids Moisture (coupling Moisture (coupling

agents)agents)

Classification of Composite MaterialsClassification of Composite Materials

11 Traditional compositesTraditional composites ndash composite materials ndash composite materials that occur in nature or have been produced by that occur in nature or have been produced by civilizations for many years civilizations for many years ExamplesExamples wood wood (cellulose fibers in lignin

matrix) concrete asphalt concrete asphalt

22 Synthetic compositesSynthetic composites - modern material - modern material systems normally associated with the systems normally associated with the manufacturing industries in which the manufacturing industries in which the components are first produced separately and components are first produced separately and then combined in a controlled way to achieve then combined in a controlled way to achieve the desired structure properties and part the desired structure properties and part geometry geometry

Classification of Classification of SyntheticSynthetic Composites Composites Based on MatrixBased on Matrix

Matrix

Reinforcement

Metal Ceramic Polymer

Metal Powder metallurgy parts ndash combining immiscible metals

Cermets (ceramic-metal composite)

Brake pads

Ceramic Cermets TiC TiCNCemented carbides ndash used in toolsFiber-reinforced metals

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer Kevlar fibers in an epoxy matrix

Elemental (Carbon Boron etc)

Fiber reinforced metalsAuto partsaerospace

Rubber with carbon (tires)Boron Carbon reinforced plastics

MMCrsquos CMCrsquos PMCrsquosMetal Matrix Composites Ceramic Matrix Comprsquos Polymer Matrix Comprsquos

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 9: Introduction and Classification of Composites

bull Critical fiber length for effective stiffening amp strengthening

fiber length15

fdc

fiber diameter

shear strength offiber-matrix interface

fiber strength in tension

Efficiency fiber lengthEfficiency fiber length

(x)

7

fiber length 15

fdc

Shorter thicker fiber

fiber length 15

fdc

(x)

Longer thinner fiber

Poorer fiber efficiency Better fiber efficiency

Why are Fibers of a Thin Diameter

1 Thinner fiber has higher ultimate strength because less chance

for inherent flaws Similar phenomenon in metals and alloys(Strength of a thin wire can be higher than its bulk material)

2 For the same volume of fibers thinner fibers has largersurface area thus has stronger bond with matrix (The totalsurface area of fibers is inversely proportional to the

diameterof fibers)

3 Thinner fiber has larger flexibility ( 1(EI)) and therefore isable to be bent without breaking (Woven fabric performs canbe made before impregnated with polymer matrix)

Composite Strength Longitudinal LoadingComposite Strength Longitudinal Loading

Continuous fibersContinuous fibers - - Estimate fiber-reinforced composite Estimate fiber-reinforced composite strength for long continuous fibers in a matrixstrength for long continuous fibers in a matrix

Longitudinal deformationLongitudinal deformation

cc = = mmVVmm + + ffVVff butbut cc = = mm = = ff volume fractionvolume fraction isostrainisostrain

Ec = Em Vm + EfVf longitudinal (extensional)

modulus

mm

ff

m

f

VE

VE

F

F f = fiber

m = matrixC-composite

Remembering E = and note this model corresponds to the ldquoupper boundrdquo for particulate composites

Matrix Matrix RResinsesins

- - The resin or The resin or polymerpolymer is the ldquogluerdquo that is the ldquogluerdquo that

holds the composite togetherholds the composite together

-The primary functions of the resin are to -The primary functions of the resin are to transfer stress between the reinforcing fiberstransfer stress between the reinforcing fibers

Examples Polyester Epoxy Vinyl Ester PolyurethaneExamples Polyester Epoxy Vinyl Ester Polyurethane

Transfer stresses between the fibers Provide a barrier against an adverse

environment Protect the surface of the fibers from

mechanical abrasion Determine inter-laminar shear strength Determine damage tolerance of composites Determine in-plane shear strength Determine the processibility of composites Determine heat resistance of composites

Role of Matrices in Composites

Role of MatrixRole of Matrix The primary roles of the matrix alloy then are to provideefficient transfer of load to the fibers and to blunt cracks inthe event that fiber failure occurs and so the matrix alloy forcontinuously reinforced composites may be chosen more fortoughness than for strength

On this basis lower strength more ductile and tougher matrix alloys may be utilized in continuously reinforced

composites

For discontinuously reinforced composites the matrix may govern composite strength-Then the choice of matrix will be influenced by consideration of the required composite strength and higher strength matrix alloys may be required

Functions of Matrix

Holds the fibres together Protects the fibres from environment

Distributes the loads evenly between fibres so that all fibres are subjected to the same amount of strain

Enhances transverse properties of a laminate Improves impact and fracture resistance of a component

Helps to avoid propagation of crack growth through the fibres by providing alternate failure path along the interface between the fibres and the matrix

Carry inter-laminar shear

Desired Properties of a Matrix

Reduced moisture absorption

Low shrinkage

Low coefficient of thermal expansion

Good flow characteristics so that it penetrates the fibre bundles completely and eliminates voids during the compactingcuring process

Must be elastic to transfer load to fibres

Desired Properties of a Matrix

Reasonable strength modulus and elongation (elongationshould be greater than fibre)

Strength at elevated temperature (depending on application)

Low temperature capability (depending on application)

Excellent chemical resistance (depending on application)

Should be easily processable into the final composite shape

Dimensional stability (maintains its shape)

FILLERSFILLERS

Control Compositesrsquo CostControl Compositesrsquo Cost Improved Mechanical PropertiesImproved Mechanical Properties Improved Chemical PropertiesImproved Chemical Properties Reduced Creep amp ShrinkageReduced Creep amp Shrinkage Low Tensile StrengthLow Tensile Strength Fire Retardant amp Chemical ResistantFire Retardant amp Chemical Resistant

TYPES OF FILLERTYPES OF FILLER Calcium CarbonateCalcium Carbonate KaolinKaolin Alumina TrihydrateAlumina Trihydrate Mica FeldsparMica Feldspar WollastoniteWollastonite Silica Talc GlassSilica Talc Glass

ADDITIVESADDITIVES

Improved Material PropertiesImproved Material Properties AestheticsAesthetics Enhanced WorkabilityEnhanced Workability Improved PerformanceImproved Performance

ADDITIVE TYPESADDITIVE TYPES

CatalystsCatalysts PromotersPromoters InhibitorsInhibitors Coloring DyesColoring Dyes Releasing AgentsReleasing Agents Antistatic AgentsAntistatic Agents Foaming AgentsFoaming Agents

Composites OfferComposites Offer High Strength to weight ratioHigh Strength to weight ratioHigh Stiffness to weight ratioHigh Stiffness to weight ratioHigh Modulus to weight ratioHigh Modulus to weight ratioLight WeightLight WeightDirectional strength Directional strength Corrosion resistance Corrosion resistance Weather resistance Weather resistance Dimensional stability Dimensional stability -low thermal conductivity -low thermal conductivity

-low -low coefficient of thermal expansioncoefficient of thermal expansion Radar transparencyRadar transparencyNon-magnetic Non-magnetic High impact strength High impact strength High High dielectricdielectric strength (insulator) strength (insulator) Low maintenance Low maintenance Long term durability Long term durability Part consolidation Part consolidation Small to large part geometry possible Small to large part geometry possible Tailored surface finish Tailored surface finish Design FlexibilityDesign Flexibility

Property comparisonProperty comparison

Material

Tensile modulus

(E) ( 2 mGN )

Tensile strength( u )

( 2 mGN )

Density ( )

( 3 cmg )

Specific modulus

( E )

Specific strength ( u )

E-Glass 724 53 254 285 138

Graphite 3900 21 190 2050 11

Boron 3850 28 263 1460 11

Kevlar ndash 49 130 28 150 87 187

Steel 210 034 ndash 21 78 269 0043 ndash

027

Aluminum alloys

70 014 ndash 062 27 259 0052 ndash

023

CompositeComposite strengthstrength depends on the following depends on the following factorsfactors

Inherent fiber Inherent fiber strength Fiber length strength Fiber length Number of flawsNumber of flaws

Fiber shape Fiber shape The bonding of the The bonding of the

fiber (equally stress fiber (equally stress distribution)distribution)

Voids Voids Moisture (coupling Moisture (coupling

agents)agents)

Classification of Composite MaterialsClassification of Composite Materials

11 Traditional compositesTraditional composites ndash composite materials ndash composite materials that occur in nature or have been produced by that occur in nature or have been produced by civilizations for many years civilizations for many years ExamplesExamples wood wood (cellulose fibers in lignin

matrix) concrete asphalt concrete asphalt

22 Synthetic compositesSynthetic composites - modern material - modern material systems normally associated with the systems normally associated with the manufacturing industries in which the manufacturing industries in which the components are first produced separately and components are first produced separately and then combined in a controlled way to achieve then combined in a controlled way to achieve the desired structure properties and part the desired structure properties and part geometry geometry

Classification of Classification of SyntheticSynthetic Composites Composites Based on MatrixBased on Matrix

Matrix

Reinforcement

Metal Ceramic Polymer

Metal Powder metallurgy parts ndash combining immiscible metals

Cermets (ceramic-metal composite)

Brake pads

Ceramic Cermets TiC TiCNCemented carbides ndash used in toolsFiber-reinforced metals

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer Kevlar fibers in an epoxy matrix

Elemental (Carbon Boron etc)

Fiber reinforced metalsAuto partsaerospace

Rubber with carbon (tires)Boron Carbon reinforced plastics

MMCrsquos CMCrsquos PMCrsquosMetal Matrix Composites Ceramic Matrix Comprsquos Polymer Matrix Comprsquos

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 10: Introduction and Classification of Composites

Efficiency fiber lengthEfficiency fiber length

(x)

7

fiber length 15

fdc

Shorter thicker fiber

fiber length 15

fdc

(x)

Longer thinner fiber

Poorer fiber efficiency Better fiber efficiency

Why are Fibers of a Thin Diameter

1 Thinner fiber has higher ultimate strength because less chance

for inherent flaws Similar phenomenon in metals and alloys(Strength of a thin wire can be higher than its bulk material)

2 For the same volume of fibers thinner fibers has largersurface area thus has stronger bond with matrix (The totalsurface area of fibers is inversely proportional to the

diameterof fibers)

3 Thinner fiber has larger flexibility ( 1(EI)) and therefore isable to be bent without breaking (Woven fabric performs canbe made before impregnated with polymer matrix)

Composite Strength Longitudinal LoadingComposite Strength Longitudinal Loading

Continuous fibersContinuous fibers - - Estimate fiber-reinforced composite Estimate fiber-reinforced composite strength for long continuous fibers in a matrixstrength for long continuous fibers in a matrix

Longitudinal deformationLongitudinal deformation

cc = = mmVVmm + + ffVVff butbut cc = = mm = = ff volume fractionvolume fraction isostrainisostrain

Ec = Em Vm + EfVf longitudinal (extensional)

modulus

mm

ff

m

f

VE

VE

F

F f = fiber

m = matrixC-composite

Remembering E = and note this model corresponds to the ldquoupper boundrdquo for particulate composites

Matrix Matrix RResinsesins

- - The resin or The resin or polymerpolymer is the ldquogluerdquo that is the ldquogluerdquo that

holds the composite togetherholds the composite together

-The primary functions of the resin are to -The primary functions of the resin are to transfer stress between the reinforcing fiberstransfer stress between the reinforcing fibers

Examples Polyester Epoxy Vinyl Ester PolyurethaneExamples Polyester Epoxy Vinyl Ester Polyurethane

Transfer stresses between the fibers Provide a barrier against an adverse

environment Protect the surface of the fibers from

mechanical abrasion Determine inter-laminar shear strength Determine damage tolerance of composites Determine in-plane shear strength Determine the processibility of composites Determine heat resistance of composites

Role of Matrices in Composites

Role of MatrixRole of Matrix The primary roles of the matrix alloy then are to provideefficient transfer of load to the fibers and to blunt cracks inthe event that fiber failure occurs and so the matrix alloy forcontinuously reinforced composites may be chosen more fortoughness than for strength

On this basis lower strength more ductile and tougher matrix alloys may be utilized in continuously reinforced

composites

For discontinuously reinforced composites the matrix may govern composite strength-Then the choice of matrix will be influenced by consideration of the required composite strength and higher strength matrix alloys may be required

Functions of Matrix

Holds the fibres together Protects the fibres from environment

Distributes the loads evenly between fibres so that all fibres are subjected to the same amount of strain

Enhances transverse properties of a laminate Improves impact and fracture resistance of a component

Helps to avoid propagation of crack growth through the fibres by providing alternate failure path along the interface between the fibres and the matrix

Carry inter-laminar shear

Desired Properties of a Matrix

Reduced moisture absorption

Low shrinkage

Low coefficient of thermal expansion

Good flow characteristics so that it penetrates the fibre bundles completely and eliminates voids during the compactingcuring process

Must be elastic to transfer load to fibres

Desired Properties of a Matrix

Reasonable strength modulus and elongation (elongationshould be greater than fibre)

Strength at elevated temperature (depending on application)

Low temperature capability (depending on application)

Excellent chemical resistance (depending on application)

Should be easily processable into the final composite shape

Dimensional stability (maintains its shape)

FILLERSFILLERS

Control Compositesrsquo CostControl Compositesrsquo Cost Improved Mechanical PropertiesImproved Mechanical Properties Improved Chemical PropertiesImproved Chemical Properties Reduced Creep amp ShrinkageReduced Creep amp Shrinkage Low Tensile StrengthLow Tensile Strength Fire Retardant amp Chemical ResistantFire Retardant amp Chemical Resistant

TYPES OF FILLERTYPES OF FILLER Calcium CarbonateCalcium Carbonate KaolinKaolin Alumina TrihydrateAlumina Trihydrate Mica FeldsparMica Feldspar WollastoniteWollastonite Silica Talc GlassSilica Talc Glass

ADDITIVESADDITIVES

Improved Material PropertiesImproved Material Properties AestheticsAesthetics Enhanced WorkabilityEnhanced Workability Improved PerformanceImproved Performance

ADDITIVE TYPESADDITIVE TYPES

CatalystsCatalysts PromotersPromoters InhibitorsInhibitors Coloring DyesColoring Dyes Releasing AgentsReleasing Agents Antistatic AgentsAntistatic Agents Foaming AgentsFoaming Agents

Composites OfferComposites Offer High Strength to weight ratioHigh Strength to weight ratioHigh Stiffness to weight ratioHigh Stiffness to weight ratioHigh Modulus to weight ratioHigh Modulus to weight ratioLight WeightLight WeightDirectional strength Directional strength Corrosion resistance Corrosion resistance Weather resistance Weather resistance Dimensional stability Dimensional stability -low thermal conductivity -low thermal conductivity

-low -low coefficient of thermal expansioncoefficient of thermal expansion Radar transparencyRadar transparencyNon-magnetic Non-magnetic High impact strength High impact strength High High dielectricdielectric strength (insulator) strength (insulator) Low maintenance Low maintenance Long term durability Long term durability Part consolidation Part consolidation Small to large part geometry possible Small to large part geometry possible Tailored surface finish Tailored surface finish Design FlexibilityDesign Flexibility

Property comparisonProperty comparison

Material

Tensile modulus

(E) ( 2 mGN )

Tensile strength( u )

( 2 mGN )

Density ( )

( 3 cmg )

Specific modulus

( E )

Specific strength ( u )

E-Glass 724 53 254 285 138

Graphite 3900 21 190 2050 11

Boron 3850 28 263 1460 11

Kevlar ndash 49 130 28 150 87 187

Steel 210 034 ndash 21 78 269 0043 ndash

027

Aluminum alloys

70 014 ndash 062 27 259 0052 ndash

023

CompositeComposite strengthstrength depends on the following depends on the following factorsfactors

Inherent fiber Inherent fiber strength Fiber length strength Fiber length Number of flawsNumber of flaws

Fiber shape Fiber shape The bonding of the The bonding of the

fiber (equally stress fiber (equally stress distribution)distribution)

Voids Voids Moisture (coupling Moisture (coupling

agents)agents)

Classification of Composite MaterialsClassification of Composite Materials

11 Traditional compositesTraditional composites ndash composite materials ndash composite materials that occur in nature or have been produced by that occur in nature or have been produced by civilizations for many years civilizations for many years ExamplesExamples wood wood (cellulose fibers in lignin

matrix) concrete asphalt concrete asphalt

22 Synthetic compositesSynthetic composites - modern material - modern material systems normally associated with the systems normally associated with the manufacturing industries in which the manufacturing industries in which the components are first produced separately and components are first produced separately and then combined in a controlled way to achieve then combined in a controlled way to achieve the desired structure properties and part the desired structure properties and part geometry geometry

Classification of Classification of SyntheticSynthetic Composites Composites Based on MatrixBased on Matrix

Matrix

Reinforcement

Metal Ceramic Polymer

Metal Powder metallurgy parts ndash combining immiscible metals

Cermets (ceramic-metal composite)

Brake pads

Ceramic Cermets TiC TiCNCemented carbides ndash used in toolsFiber-reinforced metals

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer Kevlar fibers in an epoxy matrix

Elemental (Carbon Boron etc)

Fiber reinforced metalsAuto partsaerospace

Rubber with carbon (tires)Boron Carbon reinforced plastics

MMCrsquos CMCrsquos PMCrsquosMetal Matrix Composites Ceramic Matrix Comprsquos Polymer Matrix Comprsquos

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 11: Introduction and Classification of Composites

Why are Fibers of a Thin Diameter

1 Thinner fiber has higher ultimate strength because less chance

for inherent flaws Similar phenomenon in metals and alloys(Strength of a thin wire can be higher than its bulk material)

2 For the same volume of fibers thinner fibers has largersurface area thus has stronger bond with matrix (The totalsurface area of fibers is inversely proportional to the

diameterof fibers)

3 Thinner fiber has larger flexibility ( 1(EI)) and therefore isable to be bent without breaking (Woven fabric performs canbe made before impregnated with polymer matrix)

Composite Strength Longitudinal LoadingComposite Strength Longitudinal Loading

Continuous fibersContinuous fibers - - Estimate fiber-reinforced composite Estimate fiber-reinforced composite strength for long continuous fibers in a matrixstrength for long continuous fibers in a matrix

Longitudinal deformationLongitudinal deformation

cc = = mmVVmm + + ffVVff butbut cc = = mm = = ff volume fractionvolume fraction isostrainisostrain

Ec = Em Vm + EfVf longitudinal (extensional)

modulus

mm

ff

m

f

VE

VE

F

F f = fiber

m = matrixC-composite

Remembering E = and note this model corresponds to the ldquoupper boundrdquo for particulate composites

Matrix Matrix RResinsesins

- - The resin or The resin or polymerpolymer is the ldquogluerdquo that is the ldquogluerdquo that

holds the composite togetherholds the composite together

-The primary functions of the resin are to -The primary functions of the resin are to transfer stress between the reinforcing fiberstransfer stress between the reinforcing fibers

Examples Polyester Epoxy Vinyl Ester PolyurethaneExamples Polyester Epoxy Vinyl Ester Polyurethane

Transfer stresses between the fibers Provide a barrier against an adverse

environment Protect the surface of the fibers from

mechanical abrasion Determine inter-laminar shear strength Determine damage tolerance of composites Determine in-plane shear strength Determine the processibility of composites Determine heat resistance of composites

Role of Matrices in Composites

Role of MatrixRole of Matrix The primary roles of the matrix alloy then are to provideefficient transfer of load to the fibers and to blunt cracks inthe event that fiber failure occurs and so the matrix alloy forcontinuously reinforced composites may be chosen more fortoughness than for strength

On this basis lower strength more ductile and tougher matrix alloys may be utilized in continuously reinforced

composites

For discontinuously reinforced composites the matrix may govern composite strength-Then the choice of matrix will be influenced by consideration of the required composite strength and higher strength matrix alloys may be required

Functions of Matrix

Holds the fibres together Protects the fibres from environment

Distributes the loads evenly between fibres so that all fibres are subjected to the same amount of strain

Enhances transverse properties of a laminate Improves impact and fracture resistance of a component

Helps to avoid propagation of crack growth through the fibres by providing alternate failure path along the interface between the fibres and the matrix

Carry inter-laminar shear

Desired Properties of a Matrix

Reduced moisture absorption

Low shrinkage

Low coefficient of thermal expansion

Good flow characteristics so that it penetrates the fibre bundles completely and eliminates voids during the compactingcuring process

Must be elastic to transfer load to fibres

Desired Properties of a Matrix

Reasonable strength modulus and elongation (elongationshould be greater than fibre)

Strength at elevated temperature (depending on application)

Low temperature capability (depending on application)

Excellent chemical resistance (depending on application)

Should be easily processable into the final composite shape

Dimensional stability (maintains its shape)

FILLERSFILLERS

Control Compositesrsquo CostControl Compositesrsquo Cost Improved Mechanical PropertiesImproved Mechanical Properties Improved Chemical PropertiesImproved Chemical Properties Reduced Creep amp ShrinkageReduced Creep amp Shrinkage Low Tensile StrengthLow Tensile Strength Fire Retardant amp Chemical ResistantFire Retardant amp Chemical Resistant

TYPES OF FILLERTYPES OF FILLER Calcium CarbonateCalcium Carbonate KaolinKaolin Alumina TrihydrateAlumina Trihydrate Mica FeldsparMica Feldspar WollastoniteWollastonite Silica Talc GlassSilica Talc Glass

ADDITIVESADDITIVES

Improved Material PropertiesImproved Material Properties AestheticsAesthetics Enhanced WorkabilityEnhanced Workability Improved PerformanceImproved Performance

ADDITIVE TYPESADDITIVE TYPES

CatalystsCatalysts PromotersPromoters InhibitorsInhibitors Coloring DyesColoring Dyes Releasing AgentsReleasing Agents Antistatic AgentsAntistatic Agents Foaming AgentsFoaming Agents

Composites OfferComposites Offer High Strength to weight ratioHigh Strength to weight ratioHigh Stiffness to weight ratioHigh Stiffness to weight ratioHigh Modulus to weight ratioHigh Modulus to weight ratioLight WeightLight WeightDirectional strength Directional strength Corrosion resistance Corrosion resistance Weather resistance Weather resistance Dimensional stability Dimensional stability -low thermal conductivity -low thermal conductivity

-low -low coefficient of thermal expansioncoefficient of thermal expansion Radar transparencyRadar transparencyNon-magnetic Non-magnetic High impact strength High impact strength High High dielectricdielectric strength (insulator) strength (insulator) Low maintenance Low maintenance Long term durability Long term durability Part consolidation Part consolidation Small to large part geometry possible Small to large part geometry possible Tailored surface finish Tailored surface finish Design FlexibilityDesign Flexibility

Property comparisonProperty comparison

Material

Tensile modulus

(E) ( 2 mGN )

Tensile strength( u )

( 2 mGN )

Density ( )

( 3 cmg )

Specific modulus

( E )

Specific strength ( u )

E-Glass 724 53 254 285 138

Graphite 3900 21 190 2050 11

Boron 3850 28 263 1460 11

Kevlar ndash 49 130 28 150 87 187

Steel 210 034 ndash 21 78 269 0043 ndash

027

Aluminum alloys

70 014 ndash 062 27 259 0052 ndash

023

CompositeComposite strengthstrength depends on the following depends on the following factorsfactors

Inherent fiber Inherent fiber strength Fiber length strength Fiber length Number of flawsNumber of flaws

Fiber shape Fiber shape The bonding of the The bonding of the

fiber (equally stress fiber (equally stress distribution)distribution)

Voids Voids Moisture (coupling Moisture (coupling

agents)agents)

Classification of Composite MaterialsClassification of Composite Materials

11 Traditional compositesTraditional composites ndash composite materials ndash composite materials that occur in nature or have been produced by that occur in nature or have been produced by civilizations for many years civilizations for many years ExamplesExamples wood wood (cellulose fibers in lignin

matrix) concrete asphalt concrete asphalt

22 Synthetic compositesSynthetic composites - modern material - modern material systems normally associated with the systems normally associated with the manufacturing industries in which the manufacturing industries in which the components are first produced separately and components are first produced separately and then combined in a controlled way to achieve then combined in a controlled way to achieve the desired structure properties and part the desired structure properties and part geometry geometry

Classification of Classification of SyntheticSynthetic Composites Composites Based on MatrixBased on Matrix

Matrix

Reinforcement

Metal Ceramic Polymer

Metal Powder metallurgy parts ndash combining immiscible metals

Cermets (ceramic-metal composite)

Brake pads

Ceramic Cermets TiC TiCNCemented carbides ndash used in toolsFiber-reinforced metals

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer Kevlar fibers in an epoxy matrix

Elemental (Carbon Boron etc)

Fiber reinforced metalsAuto partsaerospace

Rubber with carbon (tires)Boron Carbon reinforced plastics

MMCrsquos CMCrsquos PMCrsquosMetal Matrix Composites Ceramic Matrix Comprsquos Polymer Matrix Comprsquos

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 12: Introduction and Classification of Composites

Composite Strength Longitudinal LoadingComposite Strength Longitudinal Loading

Continuous fibersContinuous fibers - - Estimate fiber-reinforced composite Estimate fiber-reinforced composite strength for long continuous fibers in a matrixstrength for long continuous fibers in a matrix

Longitudinal deformationLongitudinal deformation

cc = = mmVVmm + + ffVVff butbut cc = = mm = = ff volume fractionvolume fraction isostrainisostrain

Ec = Em Vm + EfVf longitudinal (extensional)

modulus

mm

ff

m

f

VE

VE

F

F f = fiber

m = matrixC-composite

Remembering E = and note this model corresponds to the ldquoupper boundrdquo for particulate composites

Matrix Matrix RResinsesins

- - The resin or The resin or polymerpolymer is the ldquogluerdquo that is the ldquogluerdquo that

holds the composite togetherholds the composite together

-The primary functions of the resin are to -The primary functions of the resin are to transfer stress between the reinforcing fiberstransfer stress between the reinforcing fibers

Examples Polyester Epoxy Vinyl Ester PolyurethaneExamples Polyester Epoxy Vinyl Ester Polyurethane

Transfer stresses between the fibers Provide a barrier against an adverse

environment Protect the surface of the fibers from

mechanical abrasion Determine inter-laminar shear strength Determine damage tolerance of composites Determine in-plane shear strength Determine the processibility of composites Determine heat resistance of composites

Role of Matrices in Composites

Role of MatrixRole of Matrix The primary roles of the matrix alloy then are to provideefficient transfer of load to the fibers and to blunt cracks inthe event that fiber failure occurs and so the matrix alloy forcontinuously reinforced composites may be chosen more fortoughness than for strength

On this basis lower strength more ductile and tougher matrix alloys may be utilized in continuously reinforced

composites

For discontinuously reinforced composites the matrix may govern composite strength-Then the choice of matrix will be influenced by consideration of the required composite strength and higher strength matrix alloys may be required

Functions of Matrix

Holds the fibres together Protects the fibres from environment

Distributes the loads evenly between fibres so that all fibres are subjected to the same amount of strain

Enhances transverse properties of a laminate Improves impact and fracture resistance of a component

Helps to avoid propagation of crack growth through the fibres by providing alternate failure path along the interface between the fibres and the matrix

Carry inter-laminar shear

Desired Properties of a Matrix

Reduced moisture absorption

Low shrinkage

Low coefficient of thermal expansion

Good flow characteristics so that it penetrates the fibre bundles completely and eliminates voids during the compactingcuring process

Must be elastic to transfer load to fibres

Desired Properties of a Matrix

Reasonable strength modulus and elongation (elongationshould be greater than fibre)

Strength at elevated temperature (depending on application)

Low temperature capability (depending on application)

Excellent chemical resistance (depending on application)

Should be easily processable into the final composite shape

Dimensional stability (maintains its shape)

FILLERSFILLERS

Control Compositesrsquo CostControl Compositesrsquo Cost Improved Mechanical PropertiesImproved Mechanical Properties Improved Chemical PropertiesImproved Chemical Properties Reduced Creep amp ShrinkageReduced Creep amp Shrinkage Low Tensile StrengthLow Tensile Strength Fire Retardant amp Chemical ResistantFire Retardant amp Chemical Resistant

TYPES OF FILLERTYPES OF FILLER Calcium CarbonateCalcium Carbonate KaolinKaolin Alumina TrihydrateAlumina Trihydrate Mica FeldsparMica Feldspar WollastoniteWollastonite Silica Talc GlassSilica Talc Glass

ADDITIVESADDITIVES

Improved Material PropertiesImproved Material Properties AestheticsAesthetics Enhanced WorkabilityEnhanced Workability Improved PerformanceImproved Performance

ADDITIVE TYPESADDITIVE TYPES

CatalystsCatalysts PromotersPromoters InhibitorsInhibitors Coloring DyesColoring Dyes Releasing AgentsReleasing Agents Antistatic AgentsAntistatic Agents Foaming AgentsFoaming Agents

Composites OfferComposites Offer High Strength to weight ratioHigh Strength to weight ratioHigh Stiffness to weight ratioHigh Stiffness to weight ratioHigh Modulus to weight ratioHigh Modulus to weight ratioLight WeightLight WeightDirectional strength Directional strength Corrosion resistance Corrosion resistance Weather resistance Weather resistance Dimensional stability Dimensional stability -low thermal conductivity -low thermal conductivity

-low -low coefficient of thermal expansioncoefficient of thermal expansion Radar transparencyRadar transparencyNon-magnetic Non-magnetic High impact strength High impact strength High High dielectricdielectric strength (insulator) strength (insulator) Low maintenance Low maintenance Long term durability Long term durability Part consolidation Part consolidation Small to large part geometry possible Small to large part geometry possible Tailored surface finish Tailored surface finish Design FlexibilityDesign Flexibility

Property comparisonProperty comparison

Material

Tensile modulus

(E) ( 2 mGN )

Tensile strength( u )

( 2 mGN )

Density ( )

( 3 cmg )

Specific modulus

( E )

Specific strength ( u )

E-Glass 724 53 254 285 138

Graphite 3900 21 190 2050 11

Boron 3850 28 263 1460 11

Kevlar ndash 49 130 28 150 87 187

Steel 210 034 ndash 21 78 269 0043 ndash

027

Aluminum alloys

70 014 ndash 062 27 259 0052 ndash

023

CompositeComposite strengthstrength depends on the following depends on the following factorsfactors

Inherent fiber Inherent fiber strength Fiber length strength Fiber length Number of flawsNumber of flaws

Fiber shape Fiber shape The bonding of the The bonding of the

fiber (equally stress fiber (equally stress distribution)distribution)

Voids Voids Moisture (coupling Moisture (coupling

agents)agents)

Classification of Composite MaterialsClassification of Composite Materials

11 Traditional compositesTraditional composites ndash composite materials ndash composite materials that occur in nature or have been produced by that occur in nature or have been produced by civilizations for many years civilizations for many years ExamplesExamples wood wood (cellulose fibers in lignin

matrix) concrete asphalt concrete asphalt

22 Synthetic compositesSynthetic composites - modern material - modern material systems normally associated with the systems normally associated with the manufacturing industries in which the manufacturing industries in which the components are first produced separately and components are first produced separately and then combined in a controlled way to achieve then combined in a controlled way to achieve the desired structure properties and part the desired structure properties and part geometry geometry

Classification of Classification of SyntheticSynthetic Composites Composites Based on MatrixBased on Matrix

Matrix

Reinforcement

Metal Ceramic Polymer

Metal Powder metallurgy parts ndash combining immiscible metals

Cermets (ceramic-metal composite)

Brake pads

Ceramic Cermets TiC TiCNCemented carbides ndash used in toolsFiber-reinforced metals

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer Kevlar fibers in an epoxy matrix

Elemental (Carbon Boron etc)

Fiber reinforced metalsAuto partsaerospace

Rubber with carbon (tires)Boron Carbon reinforced plastics

MMCrsquos CMCrsquos PMCrsquosMetal Matrix Composites Ceramic Matrix Comprsquos Polymer Matrix Comprsquos

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 13: Introduction and Classification of Composites

Matrix Matrix RResinsesins

- - The resin or The resin or polymerpolymer is the ldquogluerdquo that is the ldquogluerdquo that

holds the composite togetherholds the composite together

-The primary functions of the resin are to -The primary functions of the resin are to transfer stress between the reinforcing fiberstransfer stress between the reinforcing fibers

Examples Polyester Epoxy Vinyl Ester PolyurethaneExamples Polyester Epoxy Vinyl Ester Polyurethane

Transfer stresses between the fibers Provide a barrier against an adverse

environment Protect the surface of the fibers from

mechanical abrasion Determine inter-laminar shear strength Determine damage tolerance of composites Determine in-plane shear strength Determine the processibility of composites Determine heat resistance of composites

Role of Matrices in Composites

Role of MatrixRole of Matrix The primary roles of the matrix alloy then are to provideefficient transfer of load to the fibers and to blunt cracks inthe event that fiber failure occurs and so the matrix alloy forcontinuously reinforced composites may be chosen more fortoughness than for strength

On this basis lower strength more ductile and tougher matrix alloys may be utilized in continuously reinforced

composites

For discontinuously reinforced composites the matrix may govern composite strength-Then the choice of matrix will be influenced by consideration of the required composite strength and higher strength matrix alloys may be required

Functions of Matrix

Holds the fibres together Protects the fibres from environment

Distributes the loads evenly between fibres so that all fibres are subjected to the same amount of strain

Enhances transverse properties of a laminate Improves impact and fracture resistance of a component

Helps to avoid propagation of crack growth through the fibres by providing alternate failure path along the interface between the fibres and the matrix

Carry inter-laminar shear

Desired Properties of a Matrix

Reduced moisture absorption

Low shrinkage

Low coefficient of thermal expansion

Good flow characteristics so that it penetrates the fibre bundles completely and eliminates voids during the compactingcuring process

Must be elastic to transfer load to fibres

Desired Properties of a Matrix

Reasonable strength modulus and elongation (elongationshould be greater than fibre)

Strength at elevated temperature (depending on application)

Low temperature capability (depending on application)

Excellent chemical resistance (depending on application)

Should be easily processable into the final composite shape

Dimensional stability (maintains its shape)

FILLERSFILLERS

Control Compositesrsquo CostControl Compositesrsquo Cost Improved Mechanical PropertiesImproved Mechanical Properties Improved Chemical PropertiesImproved Chemical Properties Reduced Creep amp ShrinkageReduced Creep amp Shrinkage Low Tensile StrengthLow Tensile Strength Fire Retardant amp Chemical ResistantFire Retardant amp Chemical Resistant

TYPES OF FILLERTYPES OF FILLER Calcium CarbonateCalcium Carbonate KaolinKaolin Alumina TrihydrateAlumina Trihydrate Mica FeldsparMica Feldspar WollastoniteWollastonite Silica Talc GlassSilica Talc Glass

ADDITIVESADDITIVES

Improved Material PropertiesImproved Material Properties AestheticsAesthetics Enhanced WorkabilityEnhanced Workability Improved PerformanceImproved Performance

ADDITIVE TYPESADDITIVE TYPES

CatalystsCatalysts PromotersPromoters InhibitorsInhibitors Coloring DyesColoring Dyes Releasing AgentsReleasing Agents Antistatic AgentsAntistatic Agents Foaming AgentsFoaming Agents

Composites OfferComposites Offer High Strength to weight ratioHigh Strength to weight ratioHigh Stiffness to weight ratioHigh Stiffness to weight ratioHigh Modulus to weight ratioHigh Modulus to weight ratioLight WeightLight WeightDirectional strength Directional strength Corrosion resistance Corrosion resistance Weather resistance Weather resistance Dimensional stability Dimensional stability -low thermal conductivity -low thermal conductivity

-low -low coefficient of thermal expansioncoefficient of thermal expansion Radar transparencyRadar transparencyNon-magnetic Non-magnetic High impact strength High impact strength High High dielectricdielectric strength (insulator) strength (insulator) Low maintenance Low maintenance Long term durability Long term durability Part consolidation Part consolidation Small to large part geometry possible Small to large part geometry possible Tailored surface finish Tailored surface finish Design FlexibilityDesign Flexibility

Property comparisonProperty comparison

Material

Tensile modulus

(E) ( 2 mGN )

Tensile strength( u )

( 2 mGN )

Density ( )

( 3 cmg )

Specific modulus

( E )

Specific strength ( u )

E-Glass 724 53 254 285 138

Graphite 3900 21 190 2050 11

Boron 3850 28 263 1460 11

Kevlar ndash 49 130 28 150 87 187

Steel 210 034 ndash 21 78 269 0043 ndash

027

Aluminum alloys

70 014 ndash 062 27 259 0052 ndash

023

CompositeComposite strengthstrength depends on the following depends on the following factorsfactors

Inherent fiber Inherent fiber strength Fiber length strength Fiber length Number of flawsNumber of flaws

Fiber shape Fiber shape The bonding of the The bonding of the

fiber (equally stress fiber (equally stress distribution)distribution)

Voids Voids Moisture (coupling Moisture (coupling

agents)agents)

Classification of Composite MaterialsClassification of Composite Materials

11 Traditional compositesTraditional composites ndash composite materials ndash composite materials that occur in nature or have been produced by that occur in nature or have been produced by civilizations for many years civilizations for many years ExamplesExamples wood wood (cellulose fibers in lignin

matrix) concrete asphalt concrete asphalt

22 Synthetic compositesSynthetic composites - modern material - modern material systems normally associated with the systems normally associated with the manufacturing industries in which the manufacturing industries in which the components are first produced separately and components are first produced separately and then combined in a controlled way to achieve then combined in a controlled way to achieve the desired structure properties and part the desired structure properties and part geometry geometry

Classification of Classification of SyntheticSynthetic Composites Composites Based on MatrixBased on Matrix

Matrix

Reinforcement

Metal Ceramic Polymer

Metal Powder metallurgy parts ndash combining immiscible metals

Cermets (ceramic-metal composite)

Brake pads

Ceramic Cermets TiC TiCNCemented carbides ndash used in toolsFiber-reinforced metals

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer Kevlar fibers in an epoxy matrix

Elemental (Carbon Boron etc)

Fiber reinforced metalsAuto partsaerospace

Rubber with carbon (tires)Boron Carbon reinforced plastics

MMCrsquos CMCrsquos PMCrsquosMetal Matrix Composites Ceramic Matrix Comprsquos Polymer Matrix Comprsquos

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 14: Introduction and Classification of Composites

Transfer stresses between the fibers Provide a barrier against an adverse

environment Protect the surface of the fibers from

mechanical abrasion Determine inter-laminar shear strength Determine damage tolerance of composites Determine in-plane shear strength Determine the processibility of composites Determine heat resistance of composites

Role of Matrices in Composites

Role of MatrixRole of Matrix The primary roles of the matrix alloy then are to provideefficient transfer of load to the fibers and to blunt cracks inthe event that fiber failure occurs and so the matrix alloy forcontinuously reinforced composites may be chosen more fortoughness than for strength

On this basis lower strength more ductile and tougher matrix alloys may be utilized in continuously reinforced

composites

For discontinuously reinforced composites the matrix may govern composite strength-Then the choice of matrix will be influenced by consideration of the required composite strength and higher strength matrix alloys may be required

Functions of Matrix

Holds the fibres together Protects the fibres from environment

Distributes the loads evenly between fibres so that all fibres are subjected to the same amount of strain

Enhances transverse properties of a laminate Improves impact and fracture resistance of a component

Helps to avoid propagation of crack growth through the fibres by providing alternate failure path along the interface between the fibres and the matrix

Carry inter-laminar shear

Desired Properties of a Matrix

Reduced moisture absorption

Low shrinkage

Low coefficient of thermal expansion

Good flow characteristics so that it penetrates the fibre bundles completely and eliminates voids during the compactingcuring process

Must be elastic to transfer load to fibres

Desired Properties of a Matrix

Reasonable strength modulus and elongation (elongationshould be greater than fibre)

Strength at elevated temperature (depending on application)

Low temperature capability (depending on application)

Excellent chemical resistance (depending on application)

Should be easily processable into the final composite shape

Dimensional stability (maintains its shape)

FILLERSFILLERS

Control Compositesrsquo CostControl Compositesrsquo Cost Improved Mechanical PropertiesImproved Mechanical Properties Improved Chemical PropertiesImproved Chemical Properties Reduced Creep amp ShrinkageReduced Creep amp Shrinkage Low Tensile StrengthLow Tensile Strength Fire Retardant amp Chemical ResistantFire Retardant amp Chemical Resistant

TYPES OF FILLERTYPES OF FILLER Calcium CarbonateCalcium Carbonate KaolinKaolin Alumina TrihydrateAlumina Trihydrate Mica FeldsparMica Feldspar WollastoniteWollastonite Silica Talc GlassSilica Talc Glass

ADDITIVESADDITIVES

Improved Material PropertiesImproved Material Properties AestheticsAesthetics Enhanced WorkabilityEnhanced Workability Improved PerformanceImproved Performance

ADDITIVE TYPESADDITIVE TYPES

CatalystsCatalysts PromotersPromoters InhibitorsInhibitors Coloring DyesColoring Dyes Releasing AgentsReleasing Agents Antistatic AgentsAntistatic Agents Foaming AgentsFoaming Agents

Composites OfferComposites Offer High Strength to weight ratioHigh Strength to weight ratioHigh Stiffness to weight ratioHigh Stiffness to weight ratioHigh Modulus to weight ratioHigh Modulus to weight ratioLight WeightLight WeightDirectional strength Directional strength Corrosion resistance Corrosion resistance Weather resistance Weather resistance Dimensional stability Dimensional stability -low thermal conductivity -low thermal conductivity

-low -low coefficient of thermal expansioncoefficient of thermal expansion Radar transparencyRadar transparencyNon-magnetic Non-magnetic High impact strength High impact strength High High dielectricdielectric strength (insulator) strength (insulator) Low maintenance Low maintenance Long term durability Long term durability Part consolidation Part consolidation Small to large part geometry possible Small to large part geometry possible Tailored surface finish Tailored surface finish Design FlexibilityDesign Flexibility

Property comparisonProperty comparison

Material

Tensile modulus

(E) ( 2 mGN )

Tensile strength( u )

( 2 mGN )

Density ( )

( 3 cmg )

Specific modulus

( E )

Specific strength ( u )

E-Glass 724 53 254 285 138

Graphite 3900 21 190 2050 11

Boron 3850 28 263 1460 11

Kevlar ndash 49 130 28 150 87 187

Steel 210 034 ndash 21 78 269 0043 ndash

027

Aluminum alloys

70 014 ndash 062 27 259 0052 ndash

023

CompositeComposite strengthstrength depends on the following depends on the following factorsfactors

Inherent fiber Inherent fiber strength Fiber length strength Fiber length Number of flawsNumber of flaws

Fiber shape Fiber shape The bonding of the The bonding of the

fiber (equally stress fiber (equally stress distribution)distribution)

Voids Voids Moisture (coupling Moisture (coupling

agents)agents)

Classification of Composite MaterialsClassification of Composite Materials

11 Traditional compositesTraditional composites ndash composite materials ndash composite materials that occur in nature or have been produced by that occur in nature or have been produced by civilizations for many years civilizations for many years ExamplesExamples wood wood (cellulose fibers in lignin

matrix) concrete asphalt concrete asphalt

22 Synthetic compositesSynthetic composites - modern material - modern material systems normally associated with the systems normally associated with the manufacturing industries in which the manufacturing industries in which the components are first produced separately and components are first produced separately and then combined in a controlled way to achieve then combined in a controlled way to achieve the desired structure properties and part the desired structure properties and part geometry geometry

Classification of Classification of SyntheticSynthetic Composites Composites Based on MatrixBased on Matrix

Matrix

Reinforcement

Metal Ceramic Polymer

Metal Powder metallurgy parts ndash combining immiscible metals

Cermets (ceramic-metal composite)

Brake pads

Ceramic Cermets TiC TiCNCemented carbides ndash used in toolsFiber-reinforced metals

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer Kevlar fibers in an epoxy matrix

Elemental (Carbon Boron etc)

Fiber reinforced metalsAuto partsaerospace

Rubber with carbon (tires)Boron Carbon reinforced plastics

MMCrsquos CMCrsquos PMCrsquosMetal Matrix Composites Ceramic Matrix Comprsquos Polymer Matrix Comprsquos

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 15: Introduction and Classification of Composites

Role of MatrixRole of Matrix The primary roles of the matrix alloy then are to provideefficient transfer of load to the fibers and to blunt cracks inthe event that fiber failure occurs and so the matrix alloy forcontinuously reinforced composites may be chosen more fortoughness than for strength

On this basis lower strength more ductile and tougher matrix alloys may be utilized in continuously reinforced

composites

For discontinuously reinforced composites the matrix may govern composite strength-Then the choice of matrix will be influenced by consideration of the required composite strength and higher strength matrix alloys may be required

Functions of Matrix

Holds the fibres together Protects the fibres from environment

Distributes the loads evenly between fibres so that all fibres are subjected to the same amount of strain

Enhances transverse properties of a laminate Improves impact and fracture resistance of a component

Helps to avoid propagation of crack growth through the fibres by providing alternate failure path along the interface between the fibres and the matrix

Carry inter-laminar shear

Desired Properties of a Matrix

Reduced moisture absorption

Low shrinkage

Low coefficient of thermal expansion

Good flow characteristics so that it penetrates the fibre bundles completely and eliminates voids during the compactingcuring process

Must be elastic to transfer load to fibres

Desired Properties of a Matrix

Reasonable strength modulus and elongation (elongationshould be greater than fibre)

Strength at elevated temperature (depending on application)

Low temperature capability (depending on application)

Excellent chemical resistance (depending on application)

Should be easily processable into the final composite shape

Dimensional stability (maintains its shape)

FILLERSFILLERS

Control Compositesrsquo CostControl Compositesrsquo Cost Improved Mechanical PropertiesImproved Mechanical Properties Improved Chemical PropertiesImproved Chemical Properties Reduced Creep amp ShrinkageReduced Creep amp Shrinkage Low Tensile StrengthLow Tensile Strength Fire Retardant amp Chemical ResistantFire Retardant amp Chemical Resistant

TYPES OF FILLERTYPES OF FILLER Calcium CarbonateCalcium Carbonate KaolinKaolin Alumina TrihydrateAlumina Trihydrate Mica FeldsparMica Feldspar WollastoniteWollastonite Silica Talc GlassSilica Talc Glass

ADDITIVESADDITIVES

Improved Material PropertiesImproved Material Properties AestheticsAesthetics Enhanced WorkabilityEnhanced Workability Improved PerformanceImproved Performance

ADDITIVE TYPESADDITIVE TYPES

CatalystsCatalysts PromotersPromoters InhibitorsInhibitors Coloring DyesColoring Dyes Releasing AgentsReleasing Agents Antistatic AgentsAntistatic Agents Foaming AgentsFoaming Agents

Composites OfferComposites Offer High Strength to weight ratioHigh Strength to weight ratioHigh Stiffness to weight ratioHigh Stiffness to weight ratioHigh Modulus to weight ratioHigh Modulus to weight ratioLight WeightLight WeightDirectional strength Directional strength Corrosion resistance Corrosion resistance Weather resistance Weather resistance Dimensional stability Dimensional stability -low thermal conductivity -low thermal conductivity

-low -low coefficient of thermal expansioncoefficient of thermal expansion Radar transparencyRadar transparencyNon-magnetic Non-magnetic High impact strength High impact strength High High dielectricdielectric strength (insulator) strength (insulator) Low maintenance Low maintenance Long term durability Long term durability Part consolidation Part consolidation Small to large part geometry possible Small to large part geometry possible Tailored surface finish Tailored surface finish Design FlexibilityDesign Flexibility

Property comparisonProperty comparison

Material

Tensile modulus

(E) ( 2 mGN )

Tensile strength( u )

( 2 mGN )

Density ( )

( 3 cmg )

Specific modulus

( E )

Specific strength ( u )

E-Glass 724 53 254 285 138

Graphite 3900 21 190 2050 11

Boron 3850 28 263 1460 11

Kevlar ndash 49 130 28 150 87 187

Steel 210 034 ndash 21 78 269 0043 ndash

027

Aluminum alloys

70 014 ndash 062 27 259 0052 ndash

023

CompositeComposite strengthstrength depends on the following depends on the following factorsfactors

Inherent fiber Inherent fiber strength Fiber length strength Fiber length Number of flawsNumber of flaws

Fiber shape Fiber shape The bonding of the The bonding of the

fiber (equally stress fiber (equally stress distribution)distribution)

Voids Voids Moisture (coupling Moisture (coupling

agents)agents)

Classification of Composite MaterialsClassification of Composite Materials

11 Traditional compositesTraditional composites ndash composite materials ndash composite materials that occur in nature or have been produced by that occur in nature or have been produced by civilizations for many years civilizations for many years ExamplesExamples wood wood (cellulose fibers in lignin

matrix) concrete asphalt concrete asphalt

22 Synthetic compositesSynthetic composites - modern material - modern material systems normally associated with the systems normally associated with the manufacturing industries in which the manufacturing industries in which the components are first produced separately and components are first produced separately and then combined in a controlled way to achieve then combined in a controlled way to achieve the desired structure properties and part the desired structure properties and part geometry geometry

Classification of Classification of SyntheticSynthetic Composites Composites Based on MatrixBased on Matrix

Matrix

Reinforcement

Metal Ceramic Polymer

Metal Powder metallurgy parts ndash combining immiscible metals

Cermets (ceramic-metal composite)

Brake pads

Ceramic Cermets TiC TiCNCemented carbides ndash used in toolsFiber-reinforced metals

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer Kevlar fibers in an epoxy matrix

Elemental (Carbon Boron etc)

Fiber reinforced metalsAuto partsaerospace

Rubber with carbon (tires)Boron Carbon reinforced plastics

MMCrsquos CMCrsquos PMCrsquosMetal Matrix Composites Ceramic Matrix Comprsquos Polymer Matrix Comprsquos

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 16: Introduction and Classification of Composites

Functions of Matrix

Holds the fibres together Protects the fibres from environment

Distributes the loads evenly between fibres so that all fibres are subjected to the same amount of strain

Enhances transverse properties of a laminate Improves impact and fracture resistance of a component

Helps to avoid propagation of crack growth through the fibres by providing alternate failure path along the interface between the fibres and the matrix

Carry inter-laminar shear

Desired Properties of a Matrix

Reduced moisture absorption

Low shrinkage

Low coefficient of thermal expansion

Good flow characteristics so that it penetrates the fibre bundles completely and eliminates voids during the compactingcuring process

Must be elastic to transfer load to fibres

Desired Properties of a Matrix

Reasonable strength modulus and elongation (elongationshould be greater than fibre)

Strength at elevated temperature (depending on application)

Low temperature capability (depending on application)

Excellent chemical resistance (depending on application)

Should be easily processable into the final composite shape

Dimensional stability (maintains its shape)

FILLERSFILLERS

Control Compositesrsquo CostControl Compositesrsquo Cost Improved Mechanical PropertiesImproved Mechanical Properties Improved Chemical PropertiesImproved Chemical Properties Reduced Creep amp ShrinkageReduced Creep amp Shrinkage Low Tensile StrengthLow Tensile Strength Fire Retardant amp Chemical ResistantFire Retardant amp Chemical Resistant

TYPES OF FILLERTYPES OF FILLER Calcium CarbonateCalcium Carbonate KaolinKaolin Alumina TrihydrateAlumina Trihydrate Mica FeldsparMica Feldspar WollastoniteWollastonite Silica Talc GlassSilica Talc Glass

ADDITIVESADDITIVES

Improved Material PropertiesImproved Material Properties AestheticsAesthetics Enhanced WorkabilityEnhanced Workability Improved PerformanceImproved Performance

ADDITIVE TYPESADDITIVE TYPES

CatalystsCatalysts PromotersPromoters InhibitorsInhibitors Coloring DyesColoring Dyes Releasing AgentsReleasing Agents Antistatic AgentsAntistatic Agents Foaming AgentsFoaming Agents

Composites OfferComposites Offer High Strength to weight ratioHigh Strength to weight ratioHigh Stiffness to weight ratioHigh Stiffness to weight ratioHigh Modulus to weight ratioHigh Modulus to weight ratioLight WeightLight WeightDirectional strength Directional strength Corrosion resistance Corrosion resistance Weather resistance Weather resistance Dimensional stability Dimensional stability -low thermal conductivity -low thermal conductivity

-low -low coefficient of thermal expansioncoefficient of thermal expansion Radar transparencyRadar transparencyNon-magnetic Non-magnetic High impact strength High impact strength High High dielectricdielectric strength (insulator) strength (insulator) Low maintenance Low maintenance Long term durability Long term durability Part consolidation Part consolidation Small to large part geometry possible Small to large part geometry possible Tailored surface finish Tailored surface finish Design FlexibilityDesign Flexibility

Property comparisonProperty comparison

Material

Tensile modulus

(E) ( 2 mGN )

Tensile strength( u )

( 2 mGN )

Density ( )

( 3 cmg )

Specific modulus

( E )

Specific strength ( u )

E-Glass 724 53 254 285 138

Graphite 3900 21 190 2050 11

Boron 3850 28 263 1460 11

Kevlar ndash 49 130 28 150 87 187

Steel 210 034 ndash 21 78 269 0043 ndash

027

Aluminum alloys

70 014 ndash 062 27 259 0052 ndash

023

CompositeComposite strengthstrength depends on the following depends on the following factorsfactors

Inherent fiber Inherent fiber strength Fiber length strength Fiber length Number of flawsNumber of flaws

Fiber shape Fiber shape The bonding of the The bonding of the

fiber (equally stress fiber (equally stress distribution)distribution)

Voids Voids Moisture (coupling Moisture (coupling

agents)agents)

Classification of Composite MaterialsClassification of Composite Materials

11 Traditional compositesTraditional composites ndash composite materials ndash composite materials that occur in nature or have been produced by that occur in nature or have been produced by civilizations for many years civilizations for many years ExamplesExamples wood wood (cellulose fibers in lignin

matrix) concrete asphalt concrete asphalt

22 Synthetic compositesSynthetic composites - modern material - modern material systems normally associated with the systems normally associated with the manufacturing industries in which the manufacturing industries in which the components are first produced separately and components are first produced separately and then combined in a controlled way to achieve then combined in a controlled way to achieve the desired structure properties and part the desired structure properties and part geometry geometry

Classification of Classification of SyntheticSynthetic Composites Composites Based on MatrixBased on Matrix

Matrix

Reinforcement

Metal Ceramic Polymer

Metal Powder metallurgy parts ndash combining immiscible metals

Cermets (ceramic-metal composite)

Brake pads

Ceramic Cermets TiC TiCNCemented carbides ndash used in toolsFiber-reinforced metals

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer Kevlar fibers in an epoxy matrix

Elemental (Carbon Boron etc)

Fiber reinforced metalsAuto partsaerospace

Rubber with carbon (tires)Boron Carbon reinforced plastics

MMCrsquos CMCrsquos PMCrsquosMetal Matrix Composites Ceramic Matrix Comprsquos Polymer Matrix Comprsquos

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 17: Introduction and Classification of Composites

Desired Properties of a Matrix

Reduced moisture absorption

Low shrinkage

Low coefficient of thermal expansion

Good flow characteristics so that it penetrates the fibre bundles completely and eliminates voids during the compactingcuring process

Must be elastic to transfer load to fibres

Desired Properties of a Matrix

Reasonable strength modulus and elongation (elongationshould be greater than fibre)

Strength at elevated temperature (depending on application)

Low temperature capability (depending on application)

Excellent chemical resistance (depending on application)

Should be easily processable into the final composite shape

Dimensional stability (maintains its shape)

FILLERSFILLERS

Control Compositesrsquo CostControl Compositesrsquo Cost Improved Mechanical PropertiesImproved Mechanical Properties Improved Chemical PropertiesImproved Chemical Properties Reduced Creep amp ShrinkageReduced Creep amp Shrinkage Low Tensile StrengthLow Tensile Strength Fire Retardant amp Chemical ResistantFire Retardant amp Chemical Resistant

TYPES OF FILLERTYPES OF FILLER Calcium CarbonateCalcium Carbonate KaolinKaolin Alumina TrihydrateAlumina Trihydrate Mica FeldsparMica Feldspar WollastoniteWollastonite Silica Talc GlassSilica Talc Glass

ADDITIVESADDITIVES

Improved Material PropertiesImproved Material Properties AestheticsAesthetics Enhanced WorkabilityEnhanced Workability Improved PerformanceImproved Performance

ADDITIVE TYPESADDITIVE TYPES

CatalystsCatalysts PromotersPromoters InhibitorsInhibitors Coloring DyesColoring Dyes Releasing AgentsReleasing Agents Antistatic AgentsAntistatic Agents Foaming AgentsFoaming Agents

Composites OfferComposites Offer High Strength to weight ratioHigh Strength to weight ratioHigh Stiffness to weight ratioHigh Stiffness to weight ratioHigh Modulus to weight ratioHigh Modulus to weight ratioLight WeightLight WeightDirectional strength Directional strength Corrosion resistance Corrosion resistance Weather resistance Weather resistance Dimensional stability Dimensional stability -low thermal conductivity -low thermal conductivity

-low -low coefficient of thermal expansioncoefficient of thermal expansion Radar transparencyRadar transparencyNon-magnetic Non-magnetic High impact strength High impact strength High High dielectricdielectric strength (insulator) strength (insulator) Low maintenance Low maintenance Long term durability Long term durability Part consolidation Part consolidation Small to large part geometry possible Small to large part geometry possible Tailored surface finish Tailored surface finish Design FlexibilityDesign Flexibility

Property comparisonProperty comparison

Material

Tensile modulus

(E) ( 2 mGN )

Tensile strength( u )

( 2 mGN )

Density ( )

( 3 cmg )

Specific modulus

( E )

Specific strength ( u )

E-Glass 724 53 254 285 138

Graphite 3900 21 190 2050 11

Boron 3850 28 263 1460 11

Kevlar ndash 49 130 28 150 87 187

Steel 210 034 ndash 21 78 269 0043 ndash

027

Aluminum alloys

70 014 ndash 062 27 259 0052 ndash

023

CompositeComposite strengthstrength depends on the following depends on the following factorsfactors

Inherent fiber Inherent fiber strength Fiber length strength Fiber length Number of flawsNumber of flaws

Fiber shape Fiber shape The bonding of the The bonding of the

fiber (equally stress fiber (equally stress distribution)distribution)

Voids Voids Moisture (coupling Moisture (coupling

agents)agents)

Classification of Composite MaterialsClassification of Composite Materials

11 Traditional compositesTraditional composites ndash composite materials ndash composite materials that occur in nature or have been produced by that occur in nature or have been produced by civilizations for many years civilizations for many years ExamplesExamples wood wood (cellulose fibers in lignin

matrix) concrete asphalt concrete asphalt

22 Synthetic compositesSynthetic composites - modern material - modern material systems normally associated with the systems normally associated with the manufacturing industries in which the manufacturing industries in which the components are first produced separately and components are first produced separately and then combined in a controlled way to achieve then combined in a controlled way to achieve the desired structure properties and part the desired structure properties and part geometry geometry

Classification of Classification of SyntheticSynthetic Composites Composites Based on MatrixBased on Matrix

Matrix

Reinforcement

Metal Ceramic Polymer

Metal Powder metallurgy parts ndash combining immiscible metals

Cermets (ceramic-metal composite)

Brake pads

Ceramic Cermets TiC TiCNCemented carbides ndash used in toolsFiber-reinforced metals

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer Kevlar fibers in an epoxy matrix

Elemental (Carbon Boron etc)

Fiber reinforced metalsAuto partsaerospace

Rubber with carbon (tires)Boron Carbon reinforced plastics

MMCrsquos CMCrsquos PMCrsquosMetal Matrix Composites Ceramic Matrix Comprsquos Polymer Matrix Comprsquos

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 18: Introduction and Classification of Composites

Desired Properties of a Matrix

Reasonable strength modulus and elongation (elongationshould be greater than fibre)

Strength at elevated temperature (depending on application)

Low temperature capability (depending on application)

Excellent chemical resistance (depending on application)

Should be easily processable into the final composite shape

Dimensional stability (maintains its shape)

FILLERSFILLERS

Control Compositesrsquo CostControl Compositesrsquo Cost Improved Mechanical PropertiesImproved Mechanical Properties Improved Chemical PropertiesImproved Chemical Properties Reduced Creep amp ShrinkageReduced Creep amp Shrinkage Low Tensile StrengthLow Tensile Strength Fire Retardant amp Chemical ResistantFire Retardant amp Chemical Resistant

TYPES OF FILLERTYPES OF FILLER Calcium CarbonateCalcium Carbonate KaolinKaolin Alumina TrihydrateAlumina Trihydrate Mica FeldsparMica Feldspar WollastoniteWollastonite Silica Talc GlassSilica Talc Glass

ADDITIVESADDITIVES

Improved Material PropertiesImproved Material Properties AestheticsAesthetics Enhanced WorkabilityEnhanced Workability Improved PerformanceImproved Performance

ADDITIVE TYPESADDITIVE TYPES

CatalystsCatalysts PromotersPromoters InhibitorsInhibitors Coloring DyesColoring Dyes Releasing AgentsReleasing Agents Antistatic AgentsAntistatic Agents Foaming AgentsFoaming Agents

Composites OfferComposites Offer High Strength to weight ratioHigh Strength to weight ratioHigh Stiffness to weight ratioHigh Stiffness to weight ratioHigh Modulus to weight ratioHigh Modulus to weight ratioLight WeightLight WeightDirectional strength Directional strength Corrosion resistance Corrosion resistance Weather resistance Weather resistance Dimensional stability Dimensional stability -low thermal conductivity -low thermal conductivity

-low -low coefficient of thermal expansioncoefficient of thermal expansion Radar transparencyRadar transparencyNon-magnetic Non-magnetic High impact strength High impact strength High High dielectricdielectric strength (insulator) strength (insulator) Low maintenance Low maintenance Long term durability Long term durability Part consolidation Part consolidation Small to large part geometry possible Small to large part geometry possible Tailored surface finish Tailored surface finish Design FlexibilityDesign Flexibility

Property comparisonProperty comparison

Material

Tensile modulus

(E) ( 2 mGN )

Tensile strength( u )

( 2 mGN )

Density ( )

( 3 cmg )

Specific modulus

( E )

Specific strength ( u )

E-Glass 724 53 254 285 138

Graphite 3900 21 190 2050 11

Boron 3850 28 263 1460 11

Kevlar ndash 49 130 28 150 87 187

Steel 210 034 ndash 21 78 269 0043 ndash

027

Aluminum alloys

70 014 ndash 062 27 259 0052 ndash

023

CompositeComposite strengthstrength depends on the following depends on the following factorsfactors

Inherent fiber Inherent fiber strength Fiber length strength Fiber length Number of flawsNumber of flaws

Fiber shape Fiber shape The bonding of the The bonding of the

fiber (equally stress fiber (equally stress distribution)distribution)

Voids Voids Moisture (coupling Moisture (coupling

agents)agents)

Classification of Composite MaterialsClassification of Composite Materials

11 Traditional compositesTraditional composites ndash composite materials ndash composite materials that occur in nature or have been produced by that occur in nature or have been produced by civilizations for many years civilizations for many years ExamplesExamples wood wood (cellulose fibers in lignin

matrix) concrete asphalt concrete asphalt

22 Synthetic compositesSynthetic composites - modern material - modern material systems normally associated with the systems normally associated with the manufacturing industries in which the manufacturing industries in which the components are first produced separately and components are first produced separately and then combined in a controlled way to achieve then combined in a controlled way to achieve the desired structure properties and part the desired structure properties and part geometry geometry

Classification of Classification of SyntheticSynthetic Composites Composites Based on MatrixBased on Matrix

Matrix

Reinforcement

Metal Ceramic Polymer

Metal Powder metallurgy parts ndash combining immiscible metals

Cermets (ceramic-metal composite)

Brake pads

Ceramic Cermets TiC TiCNCemented carbides ndash used in toolsFiber-reinforced metals

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer Kevlar fibers in an epoxy matrix

Elemental (Carbon Boron etc)

Fiber reinforced metalsAuto partsaerospace

Rubber with carbon (tires)Boron Carbon reinforced plastics

MMCrsquos CMCrsquos PMCrsquosMetal Matrix Composites Ceramic Matrix Comprsquos Polymer Matrix Comprsquos

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 19: Introduction and Classification of Composites

FILLERSFILLERS

Control Compositesrsquo CostControl Compositesrsquo Cost Improved Mechanical PropertiesImproved Mechanical Properties Improved Chemical PropertiesImproved Chemical Properties Reduced Creep amp ShrinkageReduced Creep amp Shrinkage Low Tensile StrengthLow Tensile Strength Fire Retardant amp Chemical ResistantFire Retardant amp Chemical Resistant

TYPES OF FILLERTYPES OF FILLER Calcium CarbonateCalcium Carbonate KaolinKaolin Alumina TrihydrateAlumina Trihydrate Mica FeldsparMica Feldspar WollastoniteWollastonite Silica Talc GlassSilica Talc Glass

ADDITIVESADDITIVES

Improved Material PropertiesImproved Material Properties AestheticsAesthetics Enhanced WorkabilityEnhanced Workability Improved PerformanceImproved Performance

ADDITIVE TYPESADDITIVE TYPES

CatalystsCatalysts PromotersPromoters InhibitorsInhibitors Coloring DyesColoring Dyes Releasing AgentsReleasing Agents Antistatic AgentsAntistatic Agents Foaming AgentsFoaming Agents

Composites OfferComposites Offer High Strength to weight ratioHigh Strength to weight ratioHigh Stiffness to weight ratioHigh Stiffness to weight ratioHigh Modulus to weight ratioHigh Modulus to weight ratioLight WeightLight WeightDirectional strength Directional strength Corrosion resistance Corrosion resistance Weather resistance Weather resistance Dimensional stability Dimensional stability -low thermal conductivity -low thermal conductivity

-low -low coefficient of thermal expansioncoefficient of thermal expansion Radar transparencyRadar transparencyNon-magnetic Non-magnetic High impact strength High impact strength High High dielectricdielectric strength (insulator) strength (insulator) Low maintenance Low maintenance Long term durability Long term durability Part consolidation Part consolidation Small to large part geometry possible Small to large part geometry possible Tailored surface finish Tailored surface finish Design FlexibilityDesign Flexibility

Property comparisonProperty comparison

Material

Tensile modulus

(E) ( 2 mGN )

Tensile strength( u )

( 2 mGN )

Density ( )

( 3 cmg )

Specific modulus

( E )

Specific strength ( u )

E-Glass 724 53 254 285 138

Graphite 3900 21 190 2050 11

Boron 3850 28 263 1460 11

Kevlar ndash 49 130 28 150 87 187

Steel 210 034 ndash 21 78 269 0043 ndash

027

Aluminum alloys

70 014 ndash 062 27 259 0052 ndash

023

CompositeComposite strengthstrength depends on the following depends on the following factorsfactors

Inherent fiber Inherent fiber strength Fiber length strength Fiber length Number of flawsNumber of flaws

Fiber shape Fiber shape The bonding of the The bonding of the

fiber (equally stress fiber (equally stress distribution)distribution)

Voids Voids Moisture (coupling Moisture (coupling

agents)agents)

Classification of Composite MaterialsClassification of Composite Materials

11 Traditional compositesTraditional composites ndash composite materials ndash composite materials that occur in nature or have been produced by that occur in nature or have been produced by civilizations for many years civilizations for many years ExamplesExamples wood wood (cellulose fibers in lignin

matrix) concrete asphalt concrete asphalt

22 Synthetic compositesSynthetic composites - modern material - modern material systems normally associated with the systems normally associated with the manufacturing industries in which the manufacturing industries in which the components are first produced separately and components are first produced separately and then combined in a controlled way to achieve then combined in a controlled way to achieve the desired structure properties and part the desired structure properties and part geometry geometry

Classification of Classification of SyntheticSynthetic Composites Composites Based on MatrixBased on Matrix

Matrix

Reinforcement

Metal Ceramic Polymer

Metal Powder metallurgy parts ndash combining immiscible metals

Cermets (ceramic-metal composite)

Brake pads

Ceramic Cermets TiC TiCNCemented carbides ndash used in toolsFiber-reinforced metals

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer Kevlar fibers in an epoxy matrix

Elemental (Carbon Boron etc)

Fiber reinforced metalsAuto partsaerospace

Rubber with carbon (tires)Boron Carbon reinforced plastics

MMCrsquos CMCrsquos PMCrsquosMetal Matrix Composites Ceramic Matrix Comprsquos Polymer Matrix Comprsquos

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 20: Introduction and Classification of Composites

TYPES OF FILLERTYPES OF FILLER Calcium CarbonateCalcium Carbonate KaolinKaolin Alumina TrihydrateAlumina Trihydrate Mica FeldsparMica Feldspar WollastoniteWollastonite Silica Talc GlassSilica Talc Glass

ADDITIVESADDITIVES

Improved Material PropertiesImproved Material Properties AestheticsAesthetics Enhanced WorkabilityEnhanced Workability Improved PerformanceImproved Performance

ADDITIVE TYPESADDITIVE TYPES

CatalystsCatalysts PromotersPromoters InhibitorsInhibitors Coloring DyesColoring Dyes Releasing AgentsReleasing Agents Antistatic AgentsAntistatic Agents Foaming AgentsFoaming Agents

Composites OfferComposites Offer High Strength to weight ratioHigh Strength to weight ratioHigh Stiffness to weight ratioHigh Stiffness to weight ratioHigh Modulus to weight ratioHigh Modulus to weight ratioLight WeightLight WeightDirectional strength Directional strength Corrosion resistance Corrosion resistance Weather resistance Weather resistance Dimensional stability Dimensional stability -low thermal conductivity -low thermal conductivity

-low -low coefficient of thermal expansioncoefficient of thermal expansion Radar transparencyRadar transparencyNon-magnetic Non-magnetic High impact strength High impact strength High High dielectricdielectric strength (insulator) strength (insulator) Low maintenance Low maintenance Long term durability Long term durability Part consolidation Part consolidation Small to large part geometry possible Small to large part geometry possible Tailored surface finish Tailored surface finish Design FlexibilityDesign Flexibility

Property comparisonProperty comparison

Material

Tensile modulus

(E) ( 2 mGN )

Tensile strength( u )

( 2 mGN )

Density ( )

( 3 cmg )

Specific modulus

( E )

Specific strength ( u )

E-Glass 724 53 254 285 138

Graphite 3900 21 190 2050 11

Boron 3850 28 263 1460 11

Kevlar ndash 49 130 28 150 87 187

Steel 210 034 ndash 21 78 269 0043 ndash

027

Aluminum alloys

70 014 ndash 062 27 259 0052 ndash

023

CompositeComposite strengthstrength depends on the following depends on the following factorsfactors

Inherent fiber Inherent fiber strength Fiber length strength Fiber length Number of flawsNumber of flaws

Fiber shape Fiber shape The bonding of the The bonding of the

fiber (equally stress fiber (equally stress distribution)distribution)

Voids Voids Moisture (coupling Moisture (coupling

agents)agents)

Classification of Composite MaterialsClassification of Composite Materials

11 Traditional compositesTraditional composites ndash composite materials ndash composite materials that occur in nature or have been produced by that occur in nature or have been produced by civilizations for many years civilizations for many years ExamplesExamples wood wood (cellulose fibers in lignin

matrix) concrete asphalt concrete asphalt

22 Synthetic compositesSynthetic composites - modern material - modern material systems normally associated with the systems normally associated with the manufacturing industries in which the manufacturing industries in which the components are first produced separately and components are first produced separately and then combined in a controlled way to achieve then combined in a controlled way to achieve the desired structure properties and part the desired structure properties and part geometry geometry

Classification of Classification of SyntheticSynthetic Composites Composites Based on MatrixBased on Matrix

Matrix

Reinforcement

Metal Ceramic Polymer

Metal Powder metallurgy parts ndash combining immiscible metals

Cermets (ceramic-metal composite)

Brake pads

Ceramic Cermets TiC TiCNCemented carbides ndash used in toolsFiber-reinforced metals

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer Kevlar fibers in an epoxy matrix

Elemental (Carbon Boron etc)

Fiber reinforced metalsAuto partsaerospace

Rubber with carbon (tires)Boron Carbon reinforced plastics

MMCrsquos CMCrsquos PMCrsquosMetal Matrix Composites Ceramic Matrix Comprsquos Polymer Matrix Comprsquos

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 21: Introduction and Classification of Composites

ADDITIVESADDITIVES

Improved Material PropertiesImproved Material Properties AestheticsAesthetics Enhanced WorkabilityEnhanced Workability Improved PerformanceImproved Performance

ADDITIVE TYPESADDITIVE TYPES

CatalystsCatalysts PromotersPromoters InhibitorsInhibitors Coloring DyesColoring Dyes Releasing AgentsReleasing Agents Antistatic AgentsAntistatic Agents Foaming AgentsFoaming Agents

Composites OfferComposites Offer High Strength to weight ratioHigh Strength to weight ratioHigh Stiffness to weight ratioHigh Stiffness to weight ratioHigh Modulus to weight ratioHigh Modulus to weight ratioLight WeightLight WeightDirectional strength Directional strength Corrosion resistance Corrosion resistance Weather resistance Weather resistance Dimensional stability Dimensional stability -low thermal conductivity -low thermal conductivity

-low -low coefficient of thermal expansioncoefficient of thermal expansion Radar transparencyRadar transparencyNon-magnetic Non-magnetic High impact strength High impact strength High High dielectricdielectric strength (insulator) strength (insulator) Low maintenance Low maintenance Long term durability Long term durability Part consolidation Part consolidation Small to large part geometry possible Small to large part geometry possible Tailored surface finish Tailored surface finish Design FlexibilityDesign Flexibility

Property comparisonProperty comparison

Material

Tensile modulus

(E) ( 2 mGN )

Tensile strength( u )

( 2 mGN )

Density ( )

( 3 cmg )

Specific modulus

( E )

Specific strength ( u )

E-Glass 724 53 254 285 138

Graphite 3900 21 190 2050 11

Boron 3850 28 263 1460 11

Kevlar ndash 49 130 28 150 87 187

Steel 210 034 ndash 21 78 269 0043 ndash

027

Aluminum alloys

70 014 ndash 062 27 259 0052 ndash

023

CompositeComposite strengthstrength depends on the following depends on the following factorsfactors

Inherent fiber Inherent fiber strength Fiber length strength Fiber length Number of flawsNumber of flaws

Fiber shape Fiber shape The bonding of the The bonding of the

fiber (equally stress fiber (equally stress distribution)distribution)

Voids Voids Moisture (coupling Moisture (coupling

agents)agents)

Classification of Composite MaterialsClassification of Composite Materials

11 Traditional compositesTraditional composites ndash composite materials ndash composite materials that occur in nature or have been produced by that occur in nature or have been produced by civilizations for many years civilizations for many years ExamplesExamples wood wood (cellulose fibers in lignin

matrix) concrete asphalt concrete asphalt

22 Synthetic compositesSynthetic composites - modern material - modern material systems normally associated with the systems normally associated with the manufacturing industries in which the manufacturing industries in which the components are first produced separately and components are first produced separately and then combined in a controlled way to achieve then combined in a controlled way to achieve the desired structure properties and part the desired structure properties and part geometry geometry

Classification of Classification of SyntheticSynthetic Composites Composites Based on MatrixBased on Matrix

Matrix

Reinforcement

Metal Ceramic Polymer

Metal Powder metallurgy parts ndash combining immiscible metals

Cermets (ceramic-metal composite)

Brake pads

Ceramic Cermets TiC TiCNCemented carbides ndash used in toolsFiber-reinforced metals

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer Kevlar fibers in an epoxy matrix

Elemental (Carbon Boron etc)

Fiber reinforced metalsAuto partsaerospace

Rubber with carbon (tires)Boron Carbon reinforced plastics

MMCrsquos CMCrsquos PMCrsquosMetal Matrix Composites Ceramic Matrix Comprsquos Polymer Matrix Comprsquos

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 22: Introduction and Classification of Composites

ADDITIVE TYPESADDITIVE TYPES

CatalystsCatalysts PromotersPromoters InhibitorsInhibitors Coloring DyesColoring Dyes Releasing AgentsReleasing Agents Antistatic AgentsAntistatic Agents Foaming AgentsFoaming Agents

Composites OfferComposites Offer High Strength to weight ratioHigh Strength to weight ratioHigh Stiffness to weight ratioHigh Stiffness to weight ratioHigh Modulus to weight ratioHigh Modulus to weight ratioLight WeightLight WeightDirectional strength Directional strength Corrosion resistance Corrosion resistance Weather resistance Weather resistance Dimensional stability Dimensional stability -low thermal conductivity -low thermal conductivity

-low -low coefficient of thermal expansioncoefficient of thermal expansion Radar transparencyRadar transparencyNon-magnetic Non-magnetic High impact strength High impact strength High High dielectricdielectric strength (insulator) strength (insulator) Low maintenance Low maintenance Long term durability Long term durability Part consolidation Part consolidation Small to large part geometry possible Small to large part geometry possible Tailored surface finish Tailored surface finish Design FlexibilityDesign Flexibility

Property comparisonProperty comparison

Material

Tensile modulus

(E) ( 2 mGN )

Tensile strength( u )

( 2 mGN )

Density ( )

( 3 cmg )

Specific modulus

( E )

Specific strength ( u )

E-Glass 724 53 254 285 138

Graphite 3900 21 190 2050 11

Boron 3850 28 263 1460 11

Kevlar ndash 49 130 28 150 87 187

Steel 210 034 ndash 21 78 269 0043 ndash

027

Aluminum alloys

70 014 ndash 062 27 259 0052 ndash

023

CompositeComposite strengthstrength depends on the following depends on the following factorsfactors

Inherent fiber Inherent fiber strength Fiber length strength Fiber length Number of flawsNumber of flaws

Fiber shape Fiber shape The bonding of the The bonding of the

fiber (equally stress fiber (equally stress distribution)distribution)

Voids Voids Moisture (coupling Moisture (coupling

agents)agents)

Classification of Composite MaterialsClassification of Composite Materials

11 Traditional compositesTraditional composites ndash composite materials ndash composite materials that occur in nature or have been produced by that occur in nature or have been produced by civilizations for many years civilizations for many years ExamplesExamples wood wood (cellulose fibers in lignin

matrix) concrete asphalt concrete asphalt

22 Synthetic compositesSynthetic composites - modern material - modern material systems normally associated with the systems normally associated with the manufacturing industries in which the manufacturing industries in which the components are first produced separately and components are first produced separately and then combined in a controlled way to achieve then combined in a controlled way to achieve the desired structure properties and part the desired structure properties and part geometry geometry

Classification of Classification of SyntheticSynthetic Composites Composites Based on MatrixBased on Matrix

Matrix

Reinforcement

Metal Ceramic Polymer

Metal Powder metallurgy parts ndash combining immiscible metals

Cermets (ceramic-metal composite)

Brake pads

Ceramic Cermets TiC TiCNCemented carbides ndash used in toolsFiber-reinforced metals

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer Kevlar fibers in an epoxy matrix

Elemental (Carbon Boron etc)

Fiber reinforced metalsAuto partsaerospace

Rubber with carbon (tires)Boron Carbon reinforced plastics

MMCrsquos CMCrsquos PMCrsquosMetal Matrix Composites Ceramic Matrix Comprsquos Polymer Matrix Comprsquos

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 23: Introduction and Classification of Composites

Composites OfferComposites Offer High Strength to weight ratioHigh Strength to weight ratioHigh Stiffness to weight ratioHigh Stiffness to weight ratioHigh Modulus to weight ratioHigh Modulus to weight ratioLight WeightLight WeightDirectional strength Directional strength Corrosion resistance Corrosion resistance Weather resistance Weather resistance Dimensional stability Dimensional stability -low thermal conductivity -low thermal conductivity

-low -low coefficient of thermal expansioncoefficient of thermal expansion Radar transparencyRadar transparencyNon-magnetic Non-magnetic High impact strength High impact strength High High dielectricdielectric strength (insulator) strength (insulator) Low maintenance Low maintenance Long term durability Long term durability Part consolidation Part consolidation Small to large part geometry possible Small to large part geometry possible Tailored surface finish Tailored surface finish Design FlexibilityDesign Flexibility

Property comparisonProperty comparison

Material

Tensile modulus

(E) ( 2 mGN )

Tensile strength( u )

( 2 mGN )

Density ( )

( 3 cmg )

Specific modulus

( E )

Specific strength ( u )

E-Glass 724 53 254 285 138

Graphite 3900 21 190 2050 11

Boron 3850 28 263 1460 11

Kevlar ndash 49 130 28 150 87 187

Steel 210 034 ndash 21 78 269 0043 ndash

027

Aluminum alloys

70 014 ndash 062 27 259 0052 ndash

023

CompositeComposite strengthstrength depends on the following depends on the following factorsfactors

Inherent fiber Inherent fiber strength Fiber length strength Fiber length Number of flawsNumber of flaws

Fiber shape Fiber shape The bonding of the The bonding of the

fiber (equally stress fiber (equally stress distribution)distribution)

Voids Voids Moisture (coupling Moisture (coupling

agents)agents)

Classification of Composite MaterialsClassification of Composite Materials

11 Traditional compositesTraditional composites ndash composite materials ndash composite materials that occur in nature or have been produced by that occur in nature or have been produced by civilizations for many years civilizations for many years ExamplesExamples wood wood (cellulose fibers in lignin

matrix) concrete asphalt concrete asphalt

22 Synthetic compositesSynthetic composites - modern material - modern material systems normally associated with the systems normally associated with the manufacturing industries in which the manufacturing industries in which the components are first produced separately and components are first produced separately and then combined in a controlled way to achieve then combined in a controlled way to achieve the desired structure properties and part the desired structure properties and part geometry geometry

Classification of Classification of SyntheticSynthetic Composites Composites Based on MatrixBased on Matrix

Matrix

Reinforcement

Metal Ceramic Polymer

Metal Powder metallurgy parts ndash combining immiscible metals

Cermets (ceramic-metal composite)

Brake pads

Ceramic Cermets TiC TiCNCemented carbides ndash used in toolsFiber-reinforced metals

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer Kevlar fibers in an epoxy matrix

Elemental (Carbon Boron etc)

Fiber reinforced metalsAuto partsaerospace

Rubber with carbon (tires)Boron Carbon reinforced plastics

MMCrsquos CMCrsquos PMCrsquosMetal Matrix Composites Ceramic Matrix Comprsquos Polymer Matrix Comprsquos

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 24: Introduction and Classification of Composites

Property comparisonProperty comparison

Material

Tensile modulus

(E) ( 2 mGN )

Tensile strength( u )

( 2 mGN )

Density ( )

( 3 cmg )

Specific modulus

( E )

Specific strength ( u )

E-Glass 724 53 254 285 138

Graphite 3900 21 190 2050 11

Boron 3850 28 263 1460 11

Kevlar ndash 49 130 28 150 87 187

Steel 210 034 ndash 21 78 269 0043 ndash

027

Aluminum alloys

70 014 ndash 062 27 259 0052 ndash

023

CompositeComposite strengthstrength depends on the following depends on the following factorsfactors

Inherent fiber Inherent fiber strength Fiber length strength Fiber length Number of flawsNumber of flaws

Fiber shape Fiber shape The bonding of the The bonding of the

fiber (equally stress fiber (equally stress distribution)distribution)

Voids Voids Moisture (coupling Moisture (coupling

agents)agents)

Classification of Composite MaterialsClassification of Composite Materials

11 Traditional compositesTraditional composites ndash composite materials ndash composite materials that occur in nature or have been produced by that occur in nature or have been produced by civilizations for many years civilizations for many years ExamplesExamples wood wood (cellulose fibers in lignin

matrix) concrete asphalt concrete asphalt

22 Synthetic compositesSynthetic composites - modern material - modern material systems normally associated with the systems normally associated with the manufacturing industries in which the manufacturing industries in which the components are first produced separately and components are first produced separately and then combined in a controlled way to achieve then combined in a controlled way to achieve the desired structure properties and part the desired structure properties and part geometry geometry

Classification of Classification of SyntheticSynthetic Composites Composites Based on MatrixBased on Matrix

Matrix

Reinforcement

Metal Ceramic Polymer

Metal Powder metallurgy parts ndash combining immiscible metals

Cermets (ceramic-metal composite)

Brake pads

Ceramic Cermets TiC TiCNCemented carbides ndash used in toolsFiber-reinforced metals

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer Kevlar fibers in an epoxy matrix

Elemental (Carbon Boron etc)

Fiber reinforced metalsAuto partsaerospace

Rubber with carbon (tires)Boron Carbon reinforced plastics

MMCrsquos CMCrsquos PMCrsquosMetal Matrix Composites Ceramic Matrix Comprsquos Polymer Matrix Comprsquos

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 25: Introduction and Classification of Composites

CompositeComposite strengthstrength depends on the following depends on the following factorsfactors

Inherent fiber Inherent fiber strength Fiber length strength Fiber length Number of flawsNumber of flaws

Fiber shape Fiber shape The bonding of the The bonding of the

fiber (equally stress fiber (equally stress distribution)distribution)

Voids Voids Moisture (coupling Moisture (coupling

agents)agents)

Classification of Composite MaterialsClassification of Composite Materials

11 Traditional compositesTraditional composites ndash composite materials ndash composite materials that occur in nature or have been produced by that occur in nature or have been produced by civilizations for many years civilizations for many years ExamplesExamples wood wood (cellulose fibers in lignin

matrix) concrete asphalt concrete asphalt

22 Synthetic compositesSynthetic composites - modern material - modern material systems normally associated with the systems normally associated with the manufacturing industries in which the manufacturing industries in which the components are first produced separately and components are first produced separately and then combined in a controlled way to achieve then combined in a controlled way to achieve the desired structure properties and part the desired structure properties and part geometry geometry

Classification of Classification of SyntheticSynthetic Composites Composites Based on MatrixBased on Matrix

Matrix

Reinforcement

Metal Ceramic Polymer

Metal Powder metallurgy parts ndash combining immiscible metals

Cermets (ceramic-metal composite)

Brake pads

Ceramic Cermets TiC TiCNCemented carbides ndash used in toolsFiber-reinforced metals

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer Kevlar fibers in an epoxy matrix

Elemental (Carbon Boron etc)

Fiber reinforced metalsAuto partsaerospace

Rubber with carbon (tires)Boron Carbon reinforced plastics

MMCrsquos CMCrsquos PMCrsquosMetal Matrix Composites Ceramic Matrix Comprsquos Polymer Matrix Comprsquos

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 26: Introduction and Classification of Composites

Classification of Composite MaterialsClassification of Composite Materials

11 Traditional compositesTraditional composites ndash composite materials ndash composite materials that occur in nature or have been produced by that occur in nature or have been produced by civilizations for many years civilizations for many years ExamplesExamples wood wood (cellulose fibers in lignin

matrix) concrete asphalt concrete asphalt

22 Synthetic compositesSynthetic composites - modern material - modern material systems normally associated with the systems normally associated with the manufacturing industries in which the manufacturing industries in which the components are first produced separately and components are first produced separately and then combined in a controlled way to achieve then combined in a controlled way to achieve the desired structure properties and part the desired structure properties and part geometry geometry

Classification of Classification of SyntheticSynthetic Composites Composites Based on MatrixBased on Matrix

Matrix

Reinforcement

Metal Ceramic Polymer

Metal Powder metallurgy parts ndash combining immiscible metals

Cermets (ceramic-metal composite)

Brake pads

Ceramic Cermets TiC TiCNCemented carbides ndash used in toolsFiber-reinforced metals

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer Kevlar fibers in an epoxy matrix

Elemental (Carbon Boron etc)

Fiber reinforced metalsAuto partsaerospace

Rubber with carbon (tires)Boron Carbon reinforced plastics

MMCrsquos CMCrsquos PMCrsquosMetal Matrix Composites Ceramic Matrix Comprsquos Polymer Matrix Comprsquos

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 27: Introduction and Classification of Composites

Classification of Classification of SyntheticSynthetic Composites Composites Based on MatrixBased on Matrix

Matrix

Reinforcement

Metal Ceramic Polymer

Metal Powder metallurgy parts ndash combining immiscible metals

Cermets (ceramic-metal composite)

Brake pads

Ceramic Cermets TiC TiCNCemented carbides ndash used in toolsFiber-reinforced metals

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer Kevlar fibers in an epoxy matrix

Elemental (Carbon Boron etc)

Fiber reinforced metalsAuto partsaerospace

Rubber with carbon (tires)Boron Carbon reinforced plastics

MMCrsquos CMCrsquos PMCrsquosMetal Matrix Composites Ceramic Matrix Comprsquos Polymer Matrix Comprsquos

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 28: Introduction and Classification of Composites

Classification of Classification of SyntheticSynthetic Composites Composites Based on reinforcementsBased on reinforcements

There are five basic types of composite materials There are five basic types of composite materials FiberFiber particleparticle flakeflake laminarlaminar or layered and or layered and filledfilled composites composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 29: Introduction and Classification of Composites

11 Fiber Composites Fiber Composites

In fiber composites the fibers reinforce along the line of their length Reinforcement may be mainly 1-D 2-D or 3-D Figure shows the three basic types of fiber orientation 1-D1-D gives gives maximummaximum strength strength

in one direction in one direction

2-D2-D gives strength in two gives strength in two directions directions

Isotropic gives strength Isotropic gives strength equally in all directions equally in all directions

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 30: Introduction and Classification of Composites

22 Particle Composites Particle Composites ParticlesParticles usually reinforce a composite equally in all directions usually reinforce a composite equally in all directions

(called (called isotropicisotropic) ) PlasticsPlastics cermetscermets andand metals metals are examples of are examples of particlesparticles

ParticlesParticles used to strengthen a matrix do not do so in the same way as used to strengthen a matrix do not do so in the same way as fibers For one thing particles are not directional like fibers Spread at fibers For one thing particles are not directional like fibers Spread at random through out a matrix particles tend to reinforce in all random through out a matrix particles tend to reinforce in all directions equallydirections equally

CermetsCermets (1)(1) OxidendashBased cermetsOxidendashBased cermets(eg Combination of Al2O3 with Cr)(eg Combination of Al2O3 with Cr) (2)(2) CarbidendashBased CermetsCarbidendashBased Cermets(eg Tungstenndashcarbide titaniumndashcarbide)(eg Tungstenndashcarbide titaniumndashcarbide) Metalndashplastic particle compositesMetalndashplastic particle composites(eg Aluminum iron(eg Aluminum iron ampamp steel copper particles) steel copper particles) Metalndashinndashmetal Particle Composites and Metalndashinndashmetal Particle Composites and

Dispersion Hardened AlloysDispersion Hardened Alloys(eg Ceramicndashoxide particles)(eg Ceramicndashoxide particles)

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 31: Introduction and Classification of Composites

33 Flake Composites Flake Composites

FlakesFlakes because of their shape because of their shape usually reinforce in usually reinforce in 2-D2-D Two Two common flake materials are common flake materials are glassglass and and micamica (Also (Also aluminumaluminum is used as is used as metal flakes)metal flakes)

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 32: Introduction and Classification of Composites

Flake CompositesFlake Composites

A A flakeflake composite consists of thin flat composite consists of thin flat flakes held together by a flakes held together by a binderbinder or placed or placed in a in a matrixmatrix Almost all flake composite Almost all flake composite matrixes are plastic resins The most matrixes are plastic resins The most important flake materials areimportant flake materials are

11 AluminumAluminum22 MicaMica33 GGlasslass

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 33: Introduction and Classification of Composites

Flake CompositesFlake Composites

Basically Basically flakesflakes will provide will provide Uniform mechanical properties in the Uniform mechanical properties in the

plane of the flakesplane of the flakes Higher strengthHigher strength Higher flexural modulus Higher flexural modulus Higher dielectric strength and heat Higher dielectric strength and heat

resistanceresistance Better resistance to penetration by Better resistance to penetration by

liquids and vaporliquids and vapor Lower costLower cost

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 34: Introduction and Classification of Composites

44 Laminar Composites Laminar Composites

Laminar Composites are composed of layers of materials

held together by matrix

LaminarLaminar composites involve two or more composites involve two or more layers of the same or different layers of the same or different materials The layers can be arranged materials The layers can be arranged in different directions to give strength in different directions to give strength where neededwhere needed Speedboat hullsSpeedboat hulls are are among the very many products of this among the very many products of this

kindkind

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 35: Introduction and Classification of Composites

Laminar CompositesLaminar Composites We can divide We can divide laminar compositeslaminar composites into three basic types into three basic types Unreinforcedndashlayer compositesUnreinforcedndashlayer composites (1) (1) AllndashMetalAllndashMetal (a) Plated and coated metals (electrogalvanized (a) Plated and coated metals (electrogalvanized

steel ndash steel plated with zinc)steel ndash steel plated with zinc) (b) Clad metals (aluminumndashclad copperndashclad)(b) Clad metals (aluminumndashclad copperndashclad) (c) Multilayer metal laminates (tungsten beryllium)(c) Multilayer metal laminates (tungsten beryllium) (2) (2) MetalndashNonmetal MetalndashNonmetal (metal with plastic rubber etc)(metal with plastic rubber etc) (3) (3) Nonmetal Nonmetal (glassndashplastic laminates etc)(glassndashplastic laminates etc)

Reinforcedndashlayer compositesReinforcedndashlayer composites (laminae and laminates) (laminae and laminates)

Combined compositesCombined composites (reinforcedndashplastic laminates (reinforcedndashplastic laminates well bonded with steel aluminum copper rubber well bonded with steel aluminum copper rubber gold etc) gold etc)

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 36: Introduction and Classification of Composites

Laminar CompositesLaminar Composites

Like all composites Like all composites laminar laminar compositescomposites aim at combining aim at combining constituents to produce properties constituents to produce properties that neither constituent alone would that neither constituent alone would have have

InIn laminar composites (Un laminar composites (Un reinforced) outer metal is not called reinforced) outer metal is not called a matrix but a a matrix but a faceface The inner metal The inner metal even if stronger is not called even if stronger is not called a a reinforcement It is called a reinforcement It is called a basebase

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 37: Introduction and Classification of Composites

Laminar CompositesLaminar Composites

A A laminalamina (laminae) (laminae) is any is any arrangement of arrangement of unidirectional unidirectional or or woven woven fibers in a matrix Usually fibers in a matrix Usually this arrangement is flat this arrangement is flat although it may be curved although it may be curved as in a shell as in a shell

A A laminatelaminate is a stack of is a stack of lamina arranged with their lamina arranged with their main reinforcement in main reinforcement in different directionsdifferent directions

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 38: Introduction and Classification of Composites

Laminate Sequence

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 39: Introduction and Classification of Composites

55 Filled Composites Filled Composites

There are two types of There are two types of filledfilled composites In composites In oneone filler materials are filler materials are added to a normal composite result in added to a normal composite result in strengthening the composite and strengthening the composite and reducing weight The reducing weight The secondsecond type of type of filled composite consists of a skeletal filled composite consists of a skeletal 3-3-DD matrix holding a second material The matrix holding a second material The most widely used composites of this most widely used composites of this kind are kind are sandwich structuressandwich structures and and honeycombshoneycombs

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 40: Introduction and Classification of Composites

Sandwich Structure ndash Foam CoreSandwich Structure ndash Foam CoreConsists of a relatively thick core of low density Consists of a relatively thick core of low density

foam bonded on both faces to thin sheets of a foam bonded on both faces to thin sheets of a different material different material

Figure 97 ‑ Laminar composite structures (b) sandwich structure using foam core

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 41: Introduction and Classification of Composites

Sandwich Structure ndash Honeycomb CoreSandwich Structure ndash Honeycomb Core An alternative to foam coreAn alternative to foam core Either foam or honeycomb achieves high Either foam or honeycomb achieves high

strength‑to‑weight and stiffness‑to‑weight ratiosstrength‑to‑weight and stiffness‑to‑weight ratios

Figure 97 ‑ Laminar composite structures (c) sandwich structure using honeycomb core

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 42: Introduction and Classification of Composites

66Combined CompositesCombined Composites It is possible to combine several different It is possible to combine several different

materials into a single composite It is also materials into a single composite It is also possible to combine several different possible to combine several different composites into a single product A good composites into a single product A good example is a example is a modern skimodern ski (combination of wood (combination of wood as natural fiber and layers as laminar as natural fiber and layers as laminar composites)composites)

Page 43: Introduction and Classification of Composites