COMPOSITE MATERIALS

What is a composite
•
Material?
Two or more chemically distinct
materials combined to have improved
properties
– Natural/synthetic
– Wood is a natural composite of cellulose fiber
and lignin.
• Cellulose provides strength and the lignin is the "glue" that bonds
and stabilizes the fiber.
• Bamboo is a wood with hollow cylindrical shape which results in a
very light yet stiff structure. Composite fishing poles and golf club
shafts copy this design.
– The ancient Egyptians manufactured composites!
• Adobe bricks are good example which was a combination of
mud and straw

2
Composites

3
 COMPOSITES
A composite material consists of two phases:
• Primary
– Forms the matrix within which the secondary
phase is imbedded
– Any of three basic material types: polymers,
metals, or ceramics
• Secondary
– Referred to as the imbedded phase or
called the reinforcing agent
– Serves to strengthen the composite (fibers,
particles, etc.)
– Can be one of the three basic materials or
an element such as carbon or boron 4
 Unique Characteristics of Composites
 A substance consisting of a minimum of 2
materials
 At least one material serves as a solid
reinforcement
 The second is a binding material (matrix)

 Binding material begins as a liquid or slurry

 Will saturate the binding material as it
solidifies
 Hold the reinforcement in a desired orientation
 Mechanical properties of the
composite determined by
 Position of the reinforcement material
 Shape of product
 Manufacturing process used
 Reinforcement materials carry the load
 Matrix material distributes the load and
protects the reinforcement material
 Classification
Composites
material

Reinforcing
Matrix materials
materials

Particulate Structural
Fiber reinforced Polymer matrix Metal matrix Ceramic matrix
reinforced composite

Ceramic (oxides.
Light metal & alloy
Large particles Continuous fiber Laminates Thermoplastic Carbides,& nitrites
(Al, Mg,Li &Ti)
Of metals)

Refractory metal
Dispersoids Discontinues fiber Sandwich panels Thermo sets Carbon
(Co,W,)

Aligned or random Glass

Classification of particulate composite
PARTICULATE
COMPOSITES

DESPERION
LARGE PARTICLE
STRENTHENED
COMPOSITES
COMPOSITES

CONCRETE

CERMETS

RUBBER
REINFORCED
FIBER
 Particulate reinforced composites
 Size and distribution of particles.

 Dispersoids are less than 10 micrometer.

 Dispersoids are used for high temperature applications.

 Composite Survey: Particle-I

Particle-reinforced Fiber-reinforced Structural

• Examples:
- Spheroidite matrix: particles:
steel ferrite (a) cementite
(ductile) (Fe 3 C )
(brittle)
60 mm

- WC/Co matrix: particles:

cemented cobalt WC
carbide (ductile) (brittle,
Vm : hard)
10-15 vol%! 600 mm

- Automobile matrix: particles:

tires rubber C
(compliant) (stiffer)
0.75 mm
 Characteristics of fibers
 Length of fiber
 Diameter or size of fiber
 Orientation of fibers
 Amount of fiber or volume fraction of fiber
 Physical and mechanical properties of fibers
 Physical and mechanical properties of matrix
 Interference properties
 Composite Survey: Fiber

Particle-reinforced Fiber-reinforced Structural

• Critical fiber length (lC) for effective stiffening & strengthening:
fiber strength in tension fiber diameter
f d
fiber length  15 shear strength of
c fiber-matrix interface
• Ex: For fiberglass, a fiber length > 15 mm is needed since this length
provides a “Continuous fiber” based on usual glass fiber properties
• Why? Longer fibers carry stress more efficiently!
Shorter, thicker fiber: Longer, thinner fiber:  d
f d fiber length  15 f
fiber length  15
c c
s (x) s (x)

Poorer fiber efficiency Better fiber efficiency

 Diameter of fibers

• Reducing the diameter of fibers has following

advantages:

Flaws is greatly reduced and strength is increased.

Contact surface area is increased.

Flexibility of fibers is greatly increased.

 Amount of fiber

 Increase in the volume fraction of fiber leads to increase in

specific property of composite.

 It is restricted to 80%.

 Below 28% the fiber do not effectively reinforce the matrix.

 Fiber Alignment
Adapted from Fig. 16.8,
Callister 7e.

aligned aligned random

continuous discontinuous
 Fiber properties

Material Density TS Specific E Specific

Gm/cc GPa Strength GPa Modulus
Gpa
E-Glass 2.58 3.45 1.34 72.5 28.1
Carbon 1.78 4.8 2.70 200 407
Boron 2.57 3.6 1.4 400 156
SiC 3.52 20 6.25 480 150
Al2O3 3.85 1.38 0.35 379 96
Aramid 1.44 4.1 2.85 131 91
(kevlar 49)
 Matrix properties

 Supports the fibers and keep them in their position,

transfers the load to strong fibers.

 Properties of the composite depends on matrix

material.
 Structural properties
 Laminar composite are designed to improve:
corrosion resistance
wear resistance
improved appearance
unusual thermal expansion properties

 Sandwich structures are designed to improve the

stiffness of a beam and doing so without adding
excessive weight.
 Composite Survey: Structural

Particle-reinforced Fiber-reinforced Structural

• Stacked and bonded fiber-reinforced sheets
-- stacking sequence: e.g., 0º/90º or 0/45/90º
-- benefit: balanced, in-plane stiffness

• Sandwich panels
-- low density, honeycomb core
-- benefit: light weight, large bending stiffness
face sheet
adhesive layer
honeycomb
 Characteristics of metal matrix
 METALS ARE CRYSTALLINE EXCEPT METALLIC GLASSES
 POSSES THERMAL AND ELECTRICAL CONDUCTIVITY
 POSSES HIGH MALLEBILITY AND DUCTILITY
 CONTAIN DEFECTS SUCH AS POINT, LINE AND
SURFACE IMPERFECTION (0.01%)
 STRONG AND TOUGH
 PLASTICALLY DEFORMED EASILY
 STRENGTHENED BY NUMBER OF STRENGHTENING
MECHANISM
Excellent strength at high temperature Very high melting point Exceptional resistance to corrosion

Excellent wear and abrasion resistance Hardness High specific gravities or density
 Polymer matrix material
 IDEAL MATRIX MATERIALS
1. CAN BE PROCESSED EASILY
2. POSSES LIGHT WEIGHT
3. OFFER DESIRABLE MECHANICAL PROPERTIES
 STRUCTURALLY MORE COMPLEX
 POOR STRENGTH AND MODULUS
 GET DEGRADED ON EXPOSURE TO UV RAYS
 CANNOT WITHSTAND HIGH TEMPERATURE
 POOR CONDUCTOR OF ELECTRICITY
 THERMAL COEFFICIENT OF EXPANSION IS HIGH
 DO NOT HAVE FIXED MELTING POINT
 POLYMER LIQUID SHRINKS ON COOLING
 Types of Polymers

One very important classification scheme is based on the response of the

polymer to heat and solvents.
1. THERMOPLASTICS
2. THERMOSETS

Polymers that reversibly soften and flow when heated or treated with an
appropriate solvent are

THERMO PLASTICS, while those that do not are THERMOSETS.

Thermoplastics include

polyethylene (PE) used for plastic bags,

polyvinyl chloride (PVC) used to make plastic pipe and vinyl raingear,
polystyrene (PS) formed into disposable drinking glasses
And children's toys.
 CERAMIC MATRIX MATERIALS
 HARD AND BRITTLE
 HAVE STRONG IONIC OR COVALENT BOND
 LOW TOUGHNESS AND LOW STRAINS TO FRACTURE
 LOW THERMAL COEFFICIENT OF EXPANSION
 LOW MECHANICAL SHOCK RESISTANCE
 HIGH ELASTIC MODULUS
 BRITTLENESS (EVEN SMALL FLAWS CAN HAVE
DISASTROUS EFFECTS)
 Why Composites are Important??
• Composites can be very strong and stiff, yet
very light in weight, so ratios of strength-to-
weight and
• stiffness-to-weight are several times greater
than steel or aluminum
• Fatigue properties are generally better than
for common engineering metals
• Toughness is often greater than most of the
metals
• Composites can be designed that do not corrode
like steel
• Possible to achieve combinations of
properties not attainable with metals,
ceramics, or polymers alone
 Disadvantages and Limitations of
Composite Materials
• Properties of many important composites are
anisotropic
• Many of the polymer-based composites are
subject to attack by chemicals or solvents
• Composite materials are generally expensive
• Manufacturing methods for shaping
composite materials are often slow and
costly
 Where are composites used?
• Automotive industry: Lighter, stronger, wear
resistance, rust‐free, aesthetics
– Car body
– Brake pads
– Drive shafts
– Fuel tanks
– Hoods
– Spoilers
• Aerospace: Lighter, stronger, temperature
resistance, smart structures, wear resistance
– Aircraft: Nose, doors, struts, trunnion, fairings,
cowlings, ailerons, outboard and inboard flaps,
stabilizers, elevators, rudders, fin tips, spoilers,
edges
– Rockets & missiles: Nose, body, pressure tanks,
frame, fuel tanks, turbo‐motor stators, etc.
– Satellites: Antennae, frames, structural parts
• Sports: Lighter, stronger, toughness, better
aesthetics, higher damping properties
– Tennis
– Bicycles
– Badminton
– Boats
– Hockey
– Golfing
– Motorcycles …
 ME 338: Manufacturing
Instructor:Processes II
Ramesh Singh; Notes: Prof. Singh/
35
Ganesh Soni
• Transportation & Infrastructure: Lighter,
stronger, toughness, damping
– Railway coaches
– Bridges
– Ships and boats
– Dams
– Truck bodies and floors
– RV bodies
• And many more industry sectors
– Biomedical industry
– Consumer goods
– Agricultural equipment
– Heavy machinery
– Computers
– Healthcare