Non-metallic Materials

MEC 201 Materials Science & Metallurgy

Unit III
27 Introduction to polymeric materials. Polymerization. Classification of polymers.
28 Processing. Properties. Applications of polymers. Select examples. Overview of refractories.
29 Glasses & ceramics – Overview.
30 Introduction to composite materials. Fiber reinforced composites.
31 Particulate reinforced composites - examples
32 Polymer matrix composites. Processing. Properties. Applications.
33 Metal matrix composites – Processing. Properties. Applications.
34 Ceramic matrix composites. Processing. Properties. Applications.
35 Smart Materials – Overview of various smart material systems. Applications.
Classification of Non-Metallic Materials

Typical Characteristics??
 Classification of Polymers
 Source  Natural or Synthetic
 Polymerization  Addition and condensation
 Thermal behavior  Thermo-plastic, Thermoset
 Structure
Co-polymers  Line or straight, Branched, Connected

Alternating Random

Blocks Grafted

Acrylonitrile butadiene
styrene (ABS)
 Polymerization Processes
Types of polymerization : Addition & Condensation
The formation of the most common polymer, polyethylene (PE), from ethylene
molecules is an example of addition or chain-growth polymerization.
Ethylene, a gas, is the monomer (single unit) and has the formula C2H4. The two
carbon atoms are joined by a double covalent bond. Each carbon atom shares
two of its electrons with the second carbon atom, and two hydrogen atoms are
bonded to each of the carbon atoms. In presence of an appropriate combination
of heat, pressure, and catalysts, the double bond between the carbon atoms is
broken and replaced with a single covalent bond.

In general, for thermoplastics, the higher the average molecular weight the
higher will be the melting temperature and the higher will be the Young’s
modulus of the polymer.
 Polymerization Processes
Types of polymerization : Addition & Condensation
Polymer chains can also form by condensation reactions, or step-growth
polymerization, producing structures and properties that resemble those of
addition polymers. In condensation polymerization, a relatively small molecule
(such as water, ethanol, methanol etc.) is formed as a result of the
polymerization reaction. This mechanism may often involve different monomers
as starting or precursor molecules. The polymerization of dimethyl terephthalate
and ethylene glycol to produce polyester is an example.
Polymeric Materials_Types_Classification
Thermoplastics are composed of long chains produced by joining together
monomers; they typically behave in a ductile manner. The chains may or may
not have branches. Individual chains are intertwined. Thermoplastics can be
amorphous or crystalline. Upon eating, thermoplastics soften and melt. They
are processed into shapes by heating to elevated temperatures.
Thermoplastics are easily recycled.

Thermosetting polymers are composed of long chains (linear or branched)

of molecules that are strongly cross-linked to one another to form three-
dimensional network structures. Network or thermosetting polymers are like a
bunch of strings that are knotted to one another in several places and not just
tangled up. Each string may have other side strings attached to it.
Thermosets are generally stronger, but more brittle, than thermoplastics.
Thermosets do not melt upon heating but begin to decompose. They cannot
easily be reprocessed after the cross-linking reaction has occurred and
hence recycling is difficult.

Elastomers known as rubbers, have an elastic deformation >200%. These

may be thermoplastics or lightly cross-linked thermosets. The polymer chains
consist of coil-like molecules that can reversibly stretch by applying a force.
 Classification of polymers Structure of Thermoplastics
Linear/Straight Branched
Solid 3-D model

3-D model space model

Linear/Straight/Chains Branched/Chains Simple 2-D model

connected connected
Effect of temperature on thermo-plastics
“E” as a function of “T”

Typical tensile behavior of a

thermo-plastic
Thermoplastics_Examples
• Will only mold once.
Thermosets
• Cross-link process (curing) formed by heat and pressure.
• Non-reversible structure cannot be softened by heating.
 Ceramic Materials
What are ceramics?
 Name derived from the Greek work “Keramikos”, which
means burnt stuff.
 Non-metallic, in-organic, crystalline materials – oxides,
nitrides, carbides and combination thereof. Very high
melting & boiling points compared to metallic materials.
 Ceramic materials are hard, strong in compression, weak in
shear and tension and are generally brittle. (Exceptions?)
 Many ceramic systems are chemically inert/stable, in
general resistant to elevated temperature oxidation.
 The high hardness enables them to be used as tool
materials (excellent cutting ability and wear resistance).
 Insulating in nature. Many applications in thermal domain.
 Dielectric properties of some ceramics make them great
candidates as sensor materials.
 Classification of Ceramics

Based on composition

Based on application
 Refractory Materials
Inorganic materials, that are heat resistant & with
excellent chemical stability.
Based on chemical composition
Acidic  SiO2, ZrO2, Al2O3
Basic  MgO, CaO
Neutral  Carbon/graphite, Cr2O3, SiC
Based on method of manufacture
Dry Pressed, Fused Cast, Hand Molded, Formed, Unformed
Based on refractoriness
Some applications of ceramic materials
Ultra-high temperature ceramics (UHTC)
 Composite Materials
 Engineered materials made from two or more constituents that
remain separate and distinct while forming the new component

 The two materials must be chemically inert with respect to each

other so that no interaction until one of the components melts, an
exception to this condition is a small degree of inter-diffusion at
the reinforcement-matrix interface to increase bonding

 One of the constituents forms a continuous matrix while the other

serves as reinforcement

 The role of the matrix is to bind the reinforcement together to

ensure the distribution of applied stress among the reinforcement

 The role of reinforcement in composite materials is primarily to

enhance the mechanical & tribological properties and in specific
cases for modifying the electrical & thermal properties
 Composite Materials
Based on matrix
• Metal matrix composites (MMC)
• Polymer matrix composites (PMC)
• Ceramic matrix composites (CMC)
Based on reinforcement or geometry
• Particulate reinforced Composites
• Whisker/Flakes reinforced composites
• Fiber reinforced composites
• Hybrid
Classification of composites
Fiber reinforced composites

aligned aligned random

continuous discontinuous
 Fiber properties
 In most fiber-reinforced composites, the fibers
are strong, stiff and lightweight.
 If the composite is to used at elevated
temperatures, the fiber should also have a high
melting temperature.
 The specific strength and specific modulus are
the two important characteristics of fibers.

TS E
Specific Strength  Specific modulus 
 
Where TS is the tensile strength, E is the elastic modulus and r is the density.
 Types of fibers
• Glass fibers In MMCs • Boron fibers
In PMCs
• Carbon fibers • Carbon fibers
• Aramid fibers • Oxide/non-oxide ceramic fibers

 Filament: a single thread like fiber

 Roving: a bundle of filaments wound to form a large strand
 Chopped strand mat: assembled from chopped filaments
bound with a binder
 Continuous filament random mat: assembled from
continuous filaments bound with a binder
 Many varieties of woven fabrics: woven from rovings
 Particulate reinforced composites

matrix: particles:
ferrite (a) cementite
Spheroidized steel (ductile) (brittle)

Some desired properties of
reinforcements
60 mm
 low density
 chemical compatibility
 thermal stability/compatibility
 high Young’s modulus/strength
 high hardness/wear resistance
 lubricity
 good processability
Particulate reinforced composites
 Drivers for metal matrix composites with “particles”
 Material choices as matrix & reinforcement
 Properties
 Application domains

Particulate vs. dispersion vs. precipitation strengthening

Typical examples of reinforcement materials/properties

Laminates vs. Sandwich structures
Stacked and bonded fiber-reinforced sheets
-- stacking sequence: e.g., 0º/90º or 0/45/90º
-- balanced, in-plane stiffness, bi-directional strength

Sandwich panels
-- low density, foams, wood, honeycomb core
-- benefit: light weight, large bending stiffness
 Metal Matrix Composites
Stir casting/Compocasting Squeeze casting

Powder metallurgy Spray forming

 MMCs_Some examples
SiC monofilament reinforced Ti6Al4V Alumina fiber reinforced Al alloy

Al alloy-SiC particulate composite Carbide tool (WC-Co) Electrical contacts

 Polymer matrix composites
Polymers Reinforcements
Thermoset Glass fibers
Phenolic E-Glass
Epoxy S-Glass
Polyester Aramid fibers (Kevlar)
PU Carbon fibers
Thermoplastics Fillers/additives
PVC The functions of the fillers/additives are to
PEEK improve processability, and/or impart desired
properties.
Nylon
Torlon Fillers Additives
Clay Release agent
Talc Pigments
Silica UV absorber
Mica Fire retardant
Lubricants
Polymer matrix composites_Processing
Hand lay-up/spray

Filament winding
 Pultrusion

Resin transfer molding

 Ceramic Matrix Composites
Why ceramic matrix composites?
 Challenges in getting monolithic ceramic materials with high strength and
toughness, as the inherent processing flaws influence the behavior.

Ceramic Matrix Composites
The fracture toughness of ceramics is improved by introduction of secondary
phases into matrix materials with the secondary phases acting as barriers to
crack propagation.
 Reinforcement with particulates or whiskers or fibers.
 The matrix is hard. Reinforcement should have high tensile strength for arrest
of crack growth.
 Bonding between the matrix and reinforcement is generally kept weak, for
facilitating an easy pull out.

 1-5 μm  10 μm
Ceramic Matrix Composites_Processing
Examples of ceramic
matrix composites
Al2O3-ZrO2 composites
SiC particulate / Si3N4 matrix composites
SiC whisker / Al2O3 matrix composites
SiC whisker / Si3N4 matrix composites
Continuous fiber / glass matrix composites
Carbon / carbon composites
SiC / SiC composites
Oxide / oxide composites

Processing methods
• Powder metallurgy
• Liquid infiltration (reactive melt &polymer impregnation/pyrolysis)
• Gaseous processing (Vapor infiltration/deposition)
Carbon-Carbon Fiber Composites
 Carbon-Carbon Fiber Composites
Properties Typical size of C-fiber

 High specific strength and stiffness

 Exceptional HT mechanical properties
 Excellent dimensional stability
 High thermal conductivity & excellent CTE
 High thermal shock resistance
 Low to moderate toughness
 Poor oxidation resistance

Applications
 Brake disks for aircrafts
 Rocket nozzles/Gas turbine components
 High temperature parts in advanced engines
 Re-entry vehicle nose (heat shield)
 Leading edges in aircrafts/space shuttle wings
Yield Strength of various materials
600

500
Superalloy
C/C Composite
400
Yield Strength (MPa)

SiC/SiC
300
Carbon Steel
Zircaloy
200

Stainless Steel
100
Graphite
0

0 400 800 1200 1600

Temperature (°C)
 Smart Materials
 Materials that react quickly to a stimulus in a
specific manner
 The change in the material can be reversible,
bringing it to its original state.

Piezoelectric materials
Shape memory alloys
Magnetic shape memory alloys
Halochromic materials
Chromogenic/photochromic