properties of polymer composite materials …2014.pdf · 2014-03-12 · properties of polymer...

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PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, PhD.

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Page 1: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

PROPERTIES OFPOLYMER COMPOSITE MATERIALS

Prof. Zaffar Mohammad Khan, PhD.

Page 2: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

From Dedaulus to Vvyln

Page 3: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

EVOLUTION OF COMPOSITES

Page 4: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

COMPOSITES IN BARJ UL ARAB

Page 5: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

COMPOSITE GROWTH RATE IN ENGINEERING INDUSTRIES

Page 6: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

THE ALL COMPOSITE WORLD

Any modern economy is built on the ability to exploit the opportunities onoffer by new and existing high value markets – such as composites

Lord Mandelson

Page 7: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

What are Composite Materials???

Composite materials aremacroscopic combination oftwo or more materialscomplimenting each othersuch that resulting producthas superior properties:

1.Matrix (Black)2.Reinforcement Fibers (White)3.Inter-phase

STRONGER THAN STEEL YET LIGHTER THAN

ALUMINIUM

Page 8: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

Matrix Constituent

Roles:

• Binds and holds reinforcement together

• Determines composite shape and geometry

• Transfers stresses to reinforcement

Types:

• Ceramic (Temp < 6000°F)• Metallic (Temp < 4000°F)• Polymeric (Temp < 600°F)

Determine

• Environmental resistance• Shelf Life• Compressive & transverse

mechanical properties of composite

Examples:• Epoxy, Polyester, Vinyl

ester, PEEK, Polycarbones

Page 9: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

Reinforcement Constituent1. Particulate: Good compression

strength but poor tensile properties, and particles in cement.

2. Flakes: Effective solvent resistant but difficult fabrication.

3. Whiskers: High degree of strength but poor crack stopping properties.

4. Fibers: Better structural properties, crack stopping properties, flexibility of design requirement by changing orientation of fibers 0°, +45°, 90°Stacking sequence

Examples: glass, carbon, kevlar & carbon fibers

Page 10: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

Fiber Architecture

Page 11: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

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ADVANTAGES OF COMPOSITE MATERIALS

• Significant weight saving which increases payload and/or range along with fuel saving.

• Maximum specific strength and stiffness make them lighter than aluminum, stronger than steel.

• Permits aero-elastic tailoring of structural components.

• Flexibility of Design• Integrated structures diminishes

application of rivets.• Enhanced fatigue life.• Absence of corrosion.

Reduced operational,manufacturing

and maintenance cost.

Page 12: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

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Comparison of Composites with Metals

Page 13: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

Aero-elastic Composite Structure

• Permits aero-elastic tailoring of structural components.

• The composite structure is tailored to meet varying aerodynamic requirements in aircrafts, cars and wind rotor blades. It reduces drag and enhances energy conservation.

Page 14: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

Flexibility of Composite Design

• The mechanical properties of the composite structures could be optimized for tensile, shear or compression loadings through proper selection of fiber types, orientation and stacking sequence

Page 15: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

Integrated Structure

• Integrated composite structure reduces rivets and associated weight which leads to integrated structure.

• Reduce operational, manufacturing and maintenance cost.

Page 16: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

The vibration damping characteristics of composites are far superior as compared to metals for following reasons;

1.Matrix visco-elastic effects andmicro-cracking

2.Blunting of crack by in fiberstransverse direction

3.Debonding and sliding of fibersin axial direction.

Influence of Vibrations on Composites

Page 17: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

Manufacturing Methods and typical Applications• Hand Lay-up Method: Ships, wind

turbine blades, reinforcement to concrete bridge columns and slabs.

• Autoclave Method: Aircraft, space equipment, racing car

• Pultrusion Method: Rod, pipe• Filament Winding Method: Rolls,

pressure vessels, fly wheels, centrifugal separation

• Resin Injection Method: Aircraft components

• Prepreg Sheet Winding Method:Golf shaft, fishing rod

• Pressure Matched-Metal Die Method: Tennis racket, badminton racket

• Injection Method: General equipment

Page 18: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

Autoclave Manufacturing

Page 19: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

Structural Analysis

Page 20: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

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Cost & WeightConsideration

GeometricalEnvelop

ManufacturingProcesses

LoadingSpectra

Conceptual DesignA creative function providing an Initial set of design drawings

Inspection

CandidateMaterialsEnvironment

Trade Off StudiesCost/Weight Considerations

ModifyConcept

Acceptable Preliminary DesignDefines materials and structural configuration,Manufacturing and tool plans, initial costs

Detail Design & EvaluationDesign and analysis of complete structure,Local details, design-to-cost evaluation, QA plans

DevelopmentAnd Testing

ModifyDesign

Production PhaseUpdating cost/weight trade studies,Manufacturing Plans, tooling etc.

Acceptable Detail Design

PrototypeManufacture

Modify(if required)

COMPOSITE DESIGN

Page 21: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

Aircraft and Automobiles

Page 22: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

Composite Structures

Page 23: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

Composites in Skiing and Cycling

Page 24: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

Medical Industry

• The composite prosthesis is beneficial for people having physical disabilities.

• Applications include leg and foot prosthetics providing weight reduction of up to 68% compared to traditional metals such as stainless steel.

Page 25: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

All Composite Car Body by Liquid Resin Infusion(Joint Venture of Academia-Industry Collaboration)

• Structural design and analysis using the Pro-E and ANSYS tools

• The pattern and mold was manufactured from carbon and glass /polyester composites.

• Resin impregnation through carbon fabric and curing using Resin Infusion Process.

• The car took part in Shell Eco Marathon Race in Malaysia and secured 26/ 120 position.

• Published in 42nd SAMPE Technical Conference Proceedings, Utah, USA [2].

• http://www.sampe.org/store/paper.aspx?pid=6280.

Page 26: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

Development of Windmill Turbine BladesResearch Initiative by Academia, Industry & Research Center

• Wind Speed: 5-7 m/ sec.• Air Density: 1.25 Kg/ m3• No of blades: 3• NACA Profile: 4527.• Rotor Blade Diameter: 2.21 m• Hub Height: 6’-10”

• Design and Analysis at NUST. • Vacuum bagging over mold

having geometry at FiberTech.• Structural testing at ACRC.

SR NO

Maximum Load (KG)

Bending StiffnessKN/M

Bending Stiffness

Downward(KN/M)

Bending Stiffness Average(KN/M)

Applied load

UpwardKN

Applied load

DownwardKN

Maximum Displacement

Upwardmm

Maximum Displacement

Downwardmm

1 10 19.45 11.85 15.65 0.14 0.10 8.25 8.252 20 18.64 12.66 15.65 0.26 0.21 15.03 14.103 30 15.30 11.21 13.25 0.34 0.29 21.17 21.17

Page 27: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

Effect of Voids on Mechanical Properties of Carbon Epoxy Composite Materials

• Carbon-epoxy specimen were prepared by vacuum bagging, VARTM and RFI.

• Specimen were tested in tension, shear and flexural loading according to ASTM and correlated with degree of porosity.

• Porosities were observed in the test specimen and correlated to mechanical properties.

1001.7

1879.86

0

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

TVBU TVIU

Stre

ss (M

Pa)

TVBU TVIU

582.76

1059.05

0.00

200.00

400.00

600.00

800.00

1000.00

1200.00

FVBU FVIU

Stre

ss(M

Pa)

FVBU FVIU

Page 28: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

Effect of Post cure on Mechanical Properties of Sandwich Composites

• The polystyrene foam, honeycomb, balsa wood cored sandwich having carbon fabric face sheets were cured/ post cured. • Edgewise, flexural tests were conducted according to ASTM C364 & C393. • Honeycomb structure demonstrated superior edgewise compression strength as compared to Styrofoam and Balsa wood. • Post curing improved the compression strength of sandwich structure

Edgewise Compressive stress of Styrofoam core sandwich structures

0.00

2.00

4.00

6.00

8.00

10.00

12.00

14.00

16.00

18.00

SF without Post cure SF with Post cure

Edge

wis

eco

mpr

essi

vest

ress

(MPa

)

Edgewise compressive strength of Honeycomb Core sandwich structures

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

40.00

HC without Post cure HC with Post cure

Edge

wis

e C

ompr

essi

ve s

tres

s(M

Pa)

Tg Comparison Chart

0

10

20

30

40

50

60

70

80

90

Poly Epoxy without PC Poly Epoxy with PC

Tem

pera

ture

(C)

Page 29: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

CONCLUSION

• Processing of composite materials may be taught. Campuses and R&D Center should be established to promote, composite science and technology.

• Advanced Composite promise to save upon energy needs in mass transportation by 5% and accelerated socio-economic development of engineering industries.

Page 30: PROPERTIES OF POLYMER COMPOSITE MATERIALS …2014.pdf · 2014-03-12 · PROPERTIES OF POLYMER COMPOSITE MATERIALS Prof. Zaffar Mohammad Khan, ... What are Composite Materials???

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THANK YOU