PROPERTIES OF

POLYMER COMPOSITE MATERIALS

Prof. Zaffar Mohammad Khan, PhD.

From Dedaulus to Vvyln
EVOLUTION OF COMPOSITES
COMPOSITES IN BARJ UL ARAB
COMPOSITE GROWTH RATE IN
ENGINEERING INDUSTRIES
 THE ALL COMPOSITE WORLD

Any modern economy is built on the ability to exploit the opportunities on

offer by new and existing high value markets – such as composites
Lord Mandelson
 What are Composite Materials???
Composite materials are
macroscopic combination of
two or more materials
complimenting each other
such that resulting product
has superior properties:

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

STRONGER THAN STEEL

YET LIGHTER THAN
ALUMINIUM
 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
 Reinforcement Constituent
1. 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
Fiber Architecture
 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.

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 Comparison of Composites with Metals

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 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.
 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
 Integrated Structure

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

• Reduce operational,
manufacturing and
maintenance cost.
 Influence of Vibrations on Composites

The vibration damping

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

1.Matrix visco-elastic effects and

micro-cracking

2.Blunting of crack by in fibers

transverse direction

3.Debonding and sliding of fibers

in axial direction.
 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
Autoclave Manufacturing
Structural Analysis
 COMPOSITE DESIGN

Cost & Weight Geometrical Manufacturing

Consideration Envelop Processes

Conceptual Design
Loading
A creative function providing an Inspection
Spectra
Initial set of design drawings

Candidate
Environment Materials
Trade Off Studies
Cost/Weight Considerations
Modify
Concept
Acceptable Preliminary Design
Defines materials and structural configuration,
Manufacturing and tool plans, initial costs

Detail Design & Evaluation Development

Design and analysis of complete structure, And Testing
Local details, design-to-cost evaluation, QA plans

Modify
Design

Acceptable Detail Design

Production Phase
Updating cost/weight trade studies,
Manufacturing Plans, tooling etc.
Prototype Modify
Manufacture (if required) 20
Aircraft and Automobiles
Composite Structures
Composites in Skiing and Cycling
 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.
 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.
 Development of Windmill Turbine Blades
Research 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 Maximum Bending Bending Bending Applied Applied Maximum Maximum

NO Load (KG) Stiffness Stiffness Stiffness load load Displacement Displacement
KN/M Downward Average Upward Downward Upward Downward
(KN/M) (KN/M) KN KN mm mm
1 10 19.45 11.85 15.65 0.14 0.10 8.25 8.25
2 20 18.64 12.66 15.65 0.26 0.21 15.03 14.10
3 30 15.30 11.21 13.25 0.34 0.29 21.17 21.17
 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.

2200 1200.00

2000 1059.05
1879.86
1800 1000.00

1600
800.00
1400
S tre s s (M P a )

S tre s s (M P a )

1200 582.76
1001.7 600.00
1000

800
400.00
600

400 200.00
200

0 0.00
TVBU TVIU FVBU FVIU

TVBU TVIU FVBU FVIU

 Effect of Post cure on Mechanical Properties of
Sandwich Composites
• The polystyrene foam, honeycomb, balsa 40.00
Edgewise compressive strength of Honeycomb Core sandwich structures

wood cored sandwich having carbon fabric 35.00

face sheets were cured/ post cured. 30.00

E d g e w is e C o m p r e s s iv e s tre s s (M P a )
• Edgewise, flexural tests were conducted 25.00

according to ASTM C364 & C393. 20.00

• Honeycomb structure demonstrated

15.00

10.00

superior edgewise compression strength as 5.00

compared to Styrofoam and Balsa wood. 0.00

HC without Post cure HC with Post cure

• Post curing improved the compression

strength of sandwich structure
Tg Comparison Chart Edgewise Compressive stress of Styrofoam core sandwich structures

90 18.00

80 16.00

70 14.00

E d g e w is e c o m p r e s s iv e s tr e s s (M P a )
60 12.00
T e m p e ra tu re (C )

50 10.00

40 8.00

30 6.00

20 4.00

10 2.00

0 0.00
Poly Epoxy without PC Poly Epoxy with PC SF without Post cure SF with Post cure
 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.
 THANK YOU

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