Structural Composite Materials
F.C. Campbell
(#05287G)
Chapter 1
Introduction to Composite Materials
A composite material can be defined
as a combination of two or more materials that
results in better properties than those of the indi-
vidual components used alone. In contrast to
metallic alloys, each material retains its separate
chemical, physical, and mechanical properties.
The two constituents are a reinforcement and a
matrix. The main advantages of composite ma-
terials are their high strength and stiffness, com-
bined with low density, when compared with
bulk materials, allowing for a weight reduction
in the finished part.
The reinforcing phase provides the strength
and stiffness. In most cases, the reinforcement is
harder, stronger, and stiffer than the matrix. The
reinforcement is usually a fiber or a particulate.
Particulate composites have dimensions that are
approximately equal in all directions. They may
be spherical, platelets, or any other regular or ir-
regular geometry. Particulate composites tend to
be much weaker and less stiff than continuous-
fiber composites, but they are usually much less
expensive. Particulate reinforced composites usu-
ally contain less reinforcement (up to 40 to 50
volume percent) due to processing difficulties
and brittleness.
A fiber has a length that is much greater than
its diameter. The length-to-diameter (l/d) ratio is
known as the aspect ratio and can vary greatly.
Continuous fibers have long aspect ratios, while
discontinuous fibers have short aspect ratios.
Continuous-fiber composites normally have a
preferred orientation, while discontinuous fibers
generally have a random orientation. Examples
of continuous reinforcements include unidirec-
tional, woven cloth, and helical winding (Fig.
1.1a), while examples of discontinuous rein-
forcements are chopped fibers and random mat
(Fig. 1.1b). Continuous-fiber composites are
often made into laminates by stacking single
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sheets of continuous fibers in different orienta-
tions to obtain the desired strength and stiffness
properties with fiber volumes as high as 60 to
70 percent. Fibers produce high-strength com-
posites because of their small diameter; they con-
tain far fewer defects (normally surface defects)
compared to the material produced in bulk. As a
general rule, the smaller the diameter of the fiber,
the higher its strength, but often the cost increases
as the diameter becomes smaller. In addition,
smaller-diameter high-strength fibers have greater
flexibility and are more amenable to fabrication
processes such as weaving or forming over radii.
Typical fibers include glass, aramid, and carbon,
which may be continuous or discontinuous.
The continuous phase is the matrix, which is a
polymer, metal, or ceramic. Polymers have low
strength and stiffness, metals have intermediate
strength and stiffness but high ductility, and ce-
ramics have high strength and stiffness but are
brittle. The matrix (continuous phase) performs
several critical functions, including maintaining
the fibers in the proper orientation and spacing
and protecting them from abrasion and the envi-
ronment. In polymer and metal matrix compos-
ites that form a strong bond between the fiber
and the matrix, the matrix transmits loads from
the matrix to the fibers through shear loading at
the interface. In ceramic matrix composites, the
objective is often to increase the toughness rather
than the strength and stiffness; therefore, a low
interfacial strength bond is desirable.
The type and quantity of the reinforcement
­determine the final properties. Figure 1.2 shows
that the highest strength and modulus are ob-
tained with continuous-fiber composites. There is
a practical limit of about 70 volume percent rein-
forcement that can be added to form a composite.
At higher percentages, there is too little matrix to
support the fibers effectively. The theoretical
2 / Structural Composite Materials
Fig. 1.1 Typical reinforcement types
strength of discontinuous-fiber composites can
approach that of continuous-fiber composites
if their aspect ratios are great enough and they
are aligned, but it is difficult in practice to main-
tain good alignment with discontinuous fibers.
Discontinuous-fiber composites are normally
somewhat random in alignment, which dramati-
cally reduces their strength and modulus. How-
ever, discontinuous-fiber composites are gen­
erally much less costly than continuous-fiber
composites. Therefore, continuous-fiber com-
posites are used where higher strength and stiff-
ness are required (but at a higher cost), and
discontinuous-fiber composites are used where
cost is the main driver and strength and stiffness
are less important.
Both the reinforcement type and the matrix af-
fect processing. The major processing routes for
polymer matrix composites are shown in Fig. 1.3.
Two types of polymer matrices are shown: ther-
mosets and thermoplastics. A thermoset starts as
a low-viscosity resin that reacts and cures during
processing, forming an intractable solid. A ther-
moplastic is a high-viscosity resin that is pro-
cessed by heating it above its melting tempera-
ture. Because a thermoset resin sets up and cures
during processing, it cannot be reprocessed by
reheating. By comparison, a thermoplastic can
be reheated above its melting temperature for ad-
ditional processing. There are processes for both
classes of resins that are more amenable to dis-
continuous fibers and others that are more ame-
nable to continuous fibers. In general, because
metal and ceramic matrix composites require
very high temperatures and sometimes high pres-
sures for processing, they are normally much
more expensive than polymer matrix composites.
However, they have much better thermal stabil-
ity, a requirement in applications where the com-
posite is exposed to high temperatures.
This book will deal with both continuous and
discontinuous polymer, metal, and ceramic matrix
 Chapter 1: Introduction to Composite Materials / 3

Fig. 1.2 Influence of reinforcement type and quantity on composite performance

Fig. 1.3 Major polymer matrix composite fabrication processes

4 / Structural Composite Materials
composites, with an emphasis on continuous-
fiber, high-performance polymer composites.
1.1 Isotropic, Anisotropic, and
Orthotropic Materials
Materials can be classified as either isotropic
or anisotropic. Isotropic materials have the same
material properties in all directions, and normal
loads create only normal strains. By compari-
son, anisotropic materials have different mate-
rial properties in all directions at a point in the
body. There are no material planes of symmetry,
and normal loads create both normal strains and
shear strains. A material is isotropic if the prop-
erties are independent of direction within the
material.
For example, consider the element of an iso-
tropic material shown in Fig. 1.4. If the material
is loaded along its 0°, 45°, and 90° directions,
the modulus of elasticity (E) is the same in each
direction (E0° = E45° = E90°). However, if the
Fig. 1.4 Element of isotropic material under stress
material is anisotropic (for example, the compos-
ite ply shown in Fig. 1.5), it has properties that
vary with direction within the material. In this
example, the moduli are different in each direc-
tion (E0° ≠ E45° ≠ E90°). While the modulus of
elasticity is used in the example, the same depen-
dence on direction can occur for other material
properties, such as ultimate strength, Poisson’s
ratio, and thermal expansion coefficient.
Bulk materials, such as metals and polymers,
are normally treated as isotropic materials, while
composites are treated as anisotropic. However,
even bulk materials such as metals can become
anisotropic––for example, if they are highly cold
worked to produce grain alignment in a certain
direction.
Consider the unidirectional fiber-reinforced
composite ply (also known as a lamina) shown
in Fig. 1.6. The coordinate system used to de-
scribe the ply is labeled the 1-2-3 axes. In this
case, the 1-axis is defined to be parallel to the
fibers (0°), the 2-axis is defined to lie within the
plane of the plate and is perpendicular to the fi-
bers (90°), and the 3-axis is defined to be normal
 Chapter 1: Introduction to Composite Materials / 5

Fig. 1.5 Element of composite ply material under stress

Fig. 1.6 Ply angle definition

6 / Structural Composite Materials
to the plane of the plate. The 1-2-3 coordinate
system is referred to as the principal material
coordinate system. If the plate is loaded parallel
to the fibers (one- or zero-degree direction), the
modulus of elasticity E11 approaches that of the
fibers. If the plate is loaded perpendicular to
the fibers in the two- or 90-degree direction, the
modulus E22 is much lower, approaching that of
the relatively less stiff matrix. Since E11 >> E22
and the modulus varies with direction within the
material, the material is anisotropic.
Composites are a subclass of anisotropic mate-
rials that are classified as orthotropic. Ortho-
tropic materials have properties that are different
in three mutually perpendicular directions. They
have three mutually perpendicular axes of sym-
metry, and a load applied parallel to these axes
produces only normal strains. However, loads
that are not applied parallel to these axes produce
both normal and shear strains. Therefore, ortho-
tropic mechanical properties are a function of
orientation.
Fig. 1.7 Shear coupling in a 45° ply. Source: Ref 1
Consider the unidirectional composite shown
in the upper portion of Fig. 1.7, where the unidi-
rectional fibers are oriented at an angle of 45 de-
grees with respect to the x-axis. In the small,
isolated square element from the gage region, be-
cause the element is initially square (in this ex-
ample), the fibers are parallel to diagonal AD of
the element. In contrast, fibers are perpendicular
to diagonal BC. This implies that the element is
stiffer along diagonal AD than along diagonal
BC. When a tensile stress is applied, the square
element deforms. Because the stiffness is higher
along diagonal AD than along diagonal BC, the
length of diagonal AD is not increased as much
as that of diagonal BC. Therefore, the initially
square element deforms into the shape of a par-
allelogram. Because the element has been dis-
torted into a parallelogram, a shear strain gxy is
induced as a result of coupling between the axial
strains exx and eyy.
If the fibers are aligned parallel to the direc-
tion of applied stress, as in the lower portion of
 Chapter 1: Introduction to Composite Materials / 7
Fig. 1.7, the coupling between exx and eyy does
not occur. In this case, the application of a ten-
sile stress produces elongation in the x-direction
and contraction in the y-direction, and the dis-
torted element remains rectangular. Therefore,
the coupling effects exhibited by composites occur
only if stress and strain are referenced to a non–
principal material coordinate system. Thus, when
the fibers are aligned parallel (0°) or perpendic-
ular (90°) to the direction of applied stress, the
lamina is known as a specially orthotropic lam-
ina (θ = 0° or 90°). A lamina that is not aligned
parallel or perpendicular to the direction of ap-
plied stress is called a general orthotropic lam-
ina (θ ≠ 0° or 90°).
1.2 Laminates
When there is a single ply or a lay-up in which
all of the layers or plies are stacked in the same
orientation, the lay-up is called a lamina. When
the plies are stacked at various angles, the lay-up
is called a laminate. Continuous-fiber compos-
Fig. 1.8 Lamina and laminate lay-ups
ites are normally laminated materials (Fig. 1.8)
in which the individual layers, plies, or laminae
are oriented in directions that will enhance the
strength in the primary load direction. Unidirec-
tional (0°) laminae are extremely strong and stiff
in the 0° direction. However, they are very weak
in the 90° direction because the load must be car-
ried by the much weaker polymeric matrix.
While a high-strength fiber can have a tensile
strength of 500 ksi (3500 MPa) or more, a typical
polymeric matrix normally has a tensile strength
of only 5 to 10 ksi (35 to 70 MPa) (Fig. 1.9). The
longitudinal tension and compression loads are
carried by the fibers, while the matrix distributes
the loads between the fibers in tension and stabi-
lizes the fibers and prevents them from buckling
in compression. The matrix is also the primary
load carrier for interlaminar shear (i.e., shear be-
tween the layers) and transverse (90°) tension.
The relative roles of the fiber and the matrix in
detemining mechanical properties are summa-
rized in Table 1.1.
Because the fiber orientation directly impacts
mechanical properties, it seems logical to orient
8 / Structural Composite Materials

Fig. 1.9 Comparison of tensile properties of fiber, matrix, and composite

Table 1.1 Effect of fiber and matrix on 1.3 Fundamental Property Relationships

mechanical properties
Dominating composite constituent When a unidirectional continuous-fiber lam-
Mechanical property Fiber Matrix ina or laminate (Fig. 1.11) is loaded in a di­
Unidirectional rection parallel to its fibers (0° or 11-direction),
0º tension √ …
0º compression √ √ the longitudinal modulus E11 can be estimated
Shear … √ from its constituent properties by using what is
90º tension … √ known as the rule of mixtures:
Laminate
√ …
Tension
Compression √ √
E11 = EfVf + EmVm (Eq 1.1)
In-plane shear √ √
Interlaminar shear … √ where Ef is the fiber modulus, Vf is the fiber vol-
ume percentage, Em is the matrix modulus, and
Vm is the matrix volume percentage.
The longitudinal tensile strength s11 also can
as many of the layers as possible in the main be estimated by the rule of mixtures:
load-carrying direction. While this approach
may work for some structures, it is usually nec- s11 = sVf + smVm (Eq 1.2)
essary to balance the load-carrying capability
in a number of different directions, such as the where sf and sm are the ultimate fiber and ma-
0°, +45°, -45°, and 90° directions. Figure 1.10 trix strengths, respectively. Because the proper-
shows a photomicrograph of a cross-plied con- ties of the fiber dominate for all practical vol-
tinuous carbon fiber/epoxy laminate. A balanced ume percentages, the values of the matrix can
laminate having equal numbers of plies in the often be ignored; therefore:
0°, +45°, –45°, and 90° degrees directions is
called a quasi-isotropic laminate, because it car- E11 ≈ EfVf (Eq 1.3)
ries equal loads in all four directions. s11 ≈ sVf (Eq 1.4)
 Chapter 1: Introduction to Composite Materials / 9

Fig. 1.10 Cross section of a cross-plied carbon/epoxy laminate

Fig. 1.11 Unidirectional continuous-fiber lamina or laminate

10 / Structural Composite Materials
Figure 1.12 shows the dominant role of the fi-
bers in determining strength and stiffness. When
loads are parallel to the fibers (0°), the ply is
much stronger and stiffer than when loads are
transverse (90°) to the fiber direction. There is a
dramatic decrease in strength and stiffness re-
sulting from only a few degrees of misalignment
off of 0°.
When the lamina shown in Fig. 1.11 is loaded
in the transverse (90° or 22-direction), the fibers
and the matrix function in series, with both car-
rying the same load. The transverse modulus of
elasticity E22 is given as:
1/E22 = Vf /Ef + Vm/Em (Eq 1.5)
Figure 1.13 shows the variation of modulus as
a function of fiber volume percentage. When the
fiber percentage is zero, the modulus is essen-
tially the modulus of the polymer, which in-
creases up to 100 percent (where it is the modu-
lus of the fiber). At all other fiber volumes, the
E22 or 90° modulus is lower than the E11 or zero
degrees modulus, because it is dependent on the
much weaker matrix.
Other rule of mixture expressions for lamina
properties include those for the Poisson’s ratio
n12 and for the shear modulus G12:
Fig. 1.12 Influence of ply angle on strength and modulus
n12 = nfVf + nmVm (Eq 1.6)
1/G12 = Vf /Gf + Vm/Gm (Eq 1.7)
These expressions are somewhat less useful
than the previous ones, because the values for
Poisson’s ratio (nf) and the shear modulus (Gf)
of the fibers are usually not readily available.
Physical properties, such as density (r), can
also be expressed using rule of mixture relations:
r12 = rfVf + rmVm (Eq 1.8)
While these micromechanics equations are
useful for a first estimation of lamina properties
when no data are available, they generally do not
yield sufficiently accurate values for design pur-
poses. For design purposes, basic lamina and
laminate properties should be determined using
actual mechanical property testing.
1.4 Composites versus Metallics
As previously discussed, the physical character-
istics of composites and metals are significantly
different. Table 1.2 compares some properties of
composites and metals. Because composites are
highly anisotropic, their in-plane strength and