Composite Design

Fundamentals
David Richardson

Contents
A review of the fundamental characteristics of
composites

Stiffness and Strength

Anisotropic
Role of fibre, matrix and interface
Composite failure

Design
Criteria and Considerations
Aircraft Composite Design Process
Analysis approach - FEA

Advantages and Disadvantages of Composites

Design Case Studies

Stiffness and Strength

Youngs modulus is a measure of how stiff a
material is
How much is stretches under a given load
Measured in GPa or GN/m2
Steel = 210 GPa, Aluminium = 70 GPa, Polymers = 3 GPa

Stress is a measure of how strong a material is

Failure stress / strength (MPa)
Aluminium example = 400 MPa

Yield stress
Aluminium example = 200 MPa

Stress Strain of Fibre & Matrix

Diagram taken from Harris (1999)

Composites versus Aluminium

Source: Aerocomp Ltd

Isotropic versus Anisotropic

Most materials are isotropic
Meaning that their properties are the same in
all directions
Metals, polymers, ceramics

Composites are anisotropic

Meaning that their properties are (may be)
different in different directions
Wood, plywood

Anisotropic Material
Benefits
We can put the material properties where we
need them
Strength, stiffness +

We do not need material where it is not

required
Saving in weight

Disadvantage
We need to understand and determine where
and in which direction we need high
performance

The Challenge of Composites

10+ fibre
options

10+ manufacturing
options

30+ matrix
options

+ many process
variations

- Many
combination
considerations

- such as tooling
and consolidation
options

- More complex design due to anisotropic materials, near net shape

manufacture & intimate link between manufacture and material properties

Composite Material

Reinforcement Phase - Fibre

Reinforcement
May be particulate, short fibres or continuous
fibres
Provides strength and stiffness +
Influences the formability & machinability of the
resulting structure

Composite Material Forms

Particulate
- microballoons (hollow microspheres)
- nano particles (sized between 1 and
100 nanometres)
Discontinuous Fibre
-Chopped strand mat
-Chipped fibres for injection moulding
(100 m long)
Continuous Fibre

Matrix Phase
The roles of the Matrix
Holds the fibres in position
Protects the fibres
Transfers loads to and from fibres

The Matrix determines

Transverse mechanical properties
Where fibres do not reinforce structure
Y-plane ? Z-plane?

Inter laminar shear characteristics

Environmental resistance (moisture, chemical, fire)
Temperature resistance
Processing/manufacturing routes

The Fibre-Matrix Interface

Has a significant effect on
Shear, transverse, flexural, impact and crack propagation
properties

The bond must have a good shear strength in order to:

transmit load between matrix and fibre
minimise ingress of corrodents
control de-bonding

There are a number of factors which affect the bond

strength including:

compatibility of resin and fibre

imperfections on surface of the fibre
finish (or size) applied to the fibre during fibre manufacture
length of the fibre

Role & Characteristics of Matrix

Consider following 3 loading conditions:
Axial compressive loads

The matrix needs to keep the fibres straight to

avoid buckling.

In-plane shear loads

Adjacent plies attempt to slide over one another.

The matrix transfers these loads, relying on
adhesion to the fibre.

Bending loads

A combination of compression, tension and

shear loads

Composite Failure
Composites tend to fail in a different way
to metals
Different failure modes
Brittle fibres in a ductile matrix
Sudden brittle failure no elasticity
Crazing and matrix cracking may occur
Unseen failure may initiate in the laminate
Hence fear due to BVID in carbon fibre structures
Inter laminar disbonding and damage

When does material fail?

Source: Gurit: Guide to Composites

Attractive Properties of Composites

Stiffness
Strength
Low mass
Part count reduction
Low cost production of
complex shapes
Low attenuation to X-rays
Radar transparent
Inherent excellent FST
properties

Corrosion resistance
Good fatigue
performance
EMI/RFI screening
Electrical insulation
Ballistic performance
Low CTE
Good Ablative properties
(resistance to erosive
processes)

Key Design Considerations

Material Selection
Processing/Fabrication Methods
Structural Considerations
Environmental Effects & Protection
Sandwich Construction

Design/Material Selection Options

Vary proportion of fibre
Vary angles of fibres
Vary consolidation of laminate (fibre volume
fraction)
Vary types of fibres
Vary type of matrix
Vary fibre-matrix interface
Vary manufacturing process
Near net shape manufacturing
Quality of resulting laminate/product

Aircraft Composite Design Process

1.
2.
3.
4.

Determine requirements and loads

Select structural configuration
Select material, fabric, thickness, style, ply sequence
Calculate laminate properties

5.

Calculate stress induced by loads

6.

Go back to 3 if stress 1.5 >1

Evaluate cost versus weight

7.

Strength, stiffness, strain to failure, etc

Go back to 2 if high cost or weight

Build & test prototype final design

Taken from Composite Aircraft Design, Martin Hollmann

Select Structural Configuration

Important to have a thorough knowledge of the
advantages and disadvantages of the various
fabrication / manufacturing techniques
Design for Manufacture

Usually a specific structural configuration is

selected for
Ease of construction
Low tooling and fabrication costs
Lightweight

Preliminary Structural Sizing

Once the type of composite structure has
been selected = preliminary structural
sizing of the components and laminates
can proceed
Using standard structural analytical
techniques
Together with simple optimization techniques
and equations

Design Mechanical Properties

Determine mechanical properties of single
oriented lamina or ply
From testing in the longitudinal and
transverse directions
Average measured properties minus two
standard deviations
Not from material suppliers published data
Because suppliers publish most optimistic data
May be difficult to repeat in laboratory
Not design data

Properties in other directions

The properties of the ply can be calculated
in other directions using a range of
possible methods
Efficiency or Krenchel factor
Hart-Smith 10% rule
Classical Laminate Analysis

Design and Analysis of Structures

Analysis of composite components is
difficult
Dynamic loads are especially hard to
consider
Design tools are less developed than
those for conventional materials
Testing is still widely used to validate
design and analysis models

Analysis Approach
Analysis only as good as the weakest
element
Usually begins with approximations
Simplified approach for initial sizing
Rule of Mixtures, experience, empirical data

Refine analysis
Use of computational tools

Analysis should always be verifiable in

some way (test)

Finite Element Analysis

Lots of FEA codes offer composite
capability
However, analysis is not as simple as with
isotropic materials

Models have to be tuned

Verification is essential
Main strength in comparison of materials
options/arrangements

Advantages of Composites

Tailor capability (directional properties)

Lower density (lower weight)
High strength and stiffness
Fatigue performance
Corrosion resistance
Wear resistance
Low heat transmission
Good electrical insulation
Low sound transmission

Further Advantages of Composites

Textured surfaces
Self colouring
Integration of parts
Economy of scale
Moulding direct to final dimensions
Efficient use of materials
Durability
Lifetime costing attractive

Disadvantages of Composites

Environmental degradation of resin dominated properties

Notch sensitivity
Impact damage
Poor through thickness properties
Variability
Properties not established until manufactured
Limited availability of design data
Reinforcement incorrectly located
Lack of codes and standards
Recycling not easy
Fire, smoke and toxicity performance

References
Composite Materials - UWE E-learning resource
David Richardson, John Burns, Aerocomp Ltd.

Composite Aircraft Design

Martin Hollmann

Design with Reinforced Plastics, a guide for

engineers and designers
Rayner M Mayer
The Design Council
Published in 1993 by Bourne Press Ltd, Bournemouth

Contact Details

Dr David Richardson
Room 1N22
Faculty of Engineering and Technology
University of the West of England
Frenchay Campus
Coldharbour Lane
Bristol
BS16 1QY
Tel: 0117 328 2223
Email: David4.Richardson@uwe.ac.uk