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UploadFile 5041
UploadFile 5041
Final: 75%
-Chapters 1 (close book), 2-4 (open book)
Targets:
-Knowing all kinds of composite materials
-Selection & applications of composite materials
-Manufacturing methods of composite materials
-Analysis of composite materials
www.Scaled.com
• Definition
• Classification
• Applications
• Manufacturing
Islamic Azad University, Najafabad Branch, A. Atrian 5
Introduction to Composite Materials
amiratrian@gmail.com
1.Definition:
Composite materials:
-A composite is a structural material that consists of two or more combined
constituents that are combined at a macroscopic level and are not soluble in each
other.
-The key is the macroscopic examination of a material wherein the components
can be identified by the naked eye.
-Different materials can be combined on a microscopic scale, such as in alloying of
metals, but the resulting material is, for all practical purposes, macroscopically
homogeneous, i.e., the components cannot be distinguished by the naked eye and
essentially act together.
History:
Natural Composites:
-Plywood in ancient Egyptians (1500 B.C)
• Wood: The lignin matrix is
-Strengthening mud bricks by straw or bamboo shoots
reinforced with cellulose fibers
-Medieval swords and armor with layers of different
• Bone: The bone-salt plates made of
metals (1800 A.D)
calcium and phosphate ions reinforce
-Glass fibers reinforced resins in boats & aircrafts
soft collagen
(1930s)
Limitations:
• High cost of fabrication Use of composites in the space shuttle
• Hard to recycle
• Repair is not a simple process compared to that for metals
• More complexity of Mechanical characterization
• Composites do not have a high combination of strength and fracture toughness
compared to metals
Islamic Azad University, Najafabad Branch, A. Atrian 8
Introduction to Composite Materials
3.Classification:
Composites:
Dispersed phase:
Purpose is to:
• Enhance matrix properties (reinforcing)
In case of the
reinforcement -Fiber: Kevlar, Glass, Carbon, Bore
Types of geometry -Flake
composites -Particulate
Structural
-Laminate
-Bimetal
Nanocomposites
-Sandwich
FGM (Functionally
Graded Material)
Long Fiber:
-Unidirectional
-Bidirectional (woven or fabric)
Lamina (Fibrous)
Short Fiber:
-Regular fibers
-Irregular fibers
-Laminate
Laminated -Bimetal
Types of
-Sandwich
composites
Particulate
Combinations of some
or all of the first three
types
Note:
Long fibers in various forms are inherently much stiffer and stronger than the
same material in bulk form:
Compare fracture stress of 20 MPa for glass plate with 2800 to 4800 MPa for glass
fibers.
Why: In fibers, the crystals are aligned along the fiber axis. Moreover, there are fewer
internal defects in fibers than in bulk material. For example, in materials that have
dislocations, the fiber form has fewer dislocations than the bulk form.
Islamic Azad University, Najafabad Branch 12
Introduction to Composite Materials
Question: What are the main reasons for using fibers of thin diameter?
• As the fibers become smaller in diameter, the chances of an inherent flaw in the
material are reduced: A steel plate may have strength of 689 MPa, while a wire made
from this steel plate can have strength of 4100 MPa.
-Organic: Kevlar
-Inorganic: Carbon, Graphite, Glass, Boron, Quartz,
Silicon Carbide, Alumina
-Metal Fibers (wire): St, Br, Ti, W, Mo
Kevlar (trade name of aramid fiber):
Types: Kevlar 29 & Kevlar 49. Both types of Kevlar fibers have similar specific
strengths, but Kevlar 49 has a higher specific stiffness.
Kevlar 29 is mainly used in bulletproof vests
vests, ropes
ropes, and cables
cables.
For CNG capsule & High performance applications in the aircraft industry use Kevlar 49.
Kevlar:
Manufacturing: The fiber is produced by making a solution of proprietary polymers
and strong acids such as sulfuric acid. The solution is then extruded into hot
cylinders at 392°F (200°C), washed, and dried on spools. The fiber is then stretched
and drawn to increase its strength and stiffness.
Quartz:
It is similar to glass fibers and is
obtained by high-speed
stretching of quartz rods made
of (under temperature of about
2200°C) fused quartz crystals or
sand.
Glass:
Glass is the most common fiber used in polymer matrix composites.
Advantages: high strength, low cost, high chemical resistance, & good insulating
properties.
Drawbacks: low elastic modulus, poor adhesion to polymers, high specific gravity,
sensitivity to abrasion(reduces tensile strength), and low fatigue strength.
Types:
E-glass (also called “fiberglass”)
“fiberglass”):: The “E” in E-glass stands for electrical because it was
designed for electrical applications. However, it is used for many other purposes now,
such as decorations and structural applications
applications.
S-glass
glass:: The “S” in S-glass stands for higher content of silica. It retains its strength at
high temperatures compared to E-glass and has higher fatigue strength. It is used
mainly for aerospace applications
applications.
C-glass
glass:: The “C” stands for corrosion. It is used in chemical environments, such as
storage tanks
R-glass
glass:: used in structural applications such as construction
D-glass
glass:: (dielectric) used for applications requiring low dielectric constants, such as
radomes (i.e: radar+dome)
A-glass
glass:: (appearance) used to improve surface appearance.
Combination types such as E-CR glass (“E-CR” stands for electrical and corrosion
resistance) and AR glass (alkali resistant) also exist.
Glass:
Manufacturing: Glass fibers are made generally by
drawing from a melt. The melt is formed in a refractory
furnace at about 2550
2550°°F (1400°C) from a mixture that
includes sand, limestone, and alumina. The melt is stirred
and maintained at a constant temperature. It passes
through as many as 250 heated platinum alloy nozzles of
about 394 μin (10μm) diameter, where it is drawn into
filaments of needed size at high speeds of about 361 mi/h
(25 m/s). These fibers are sprayed with an organic sizing
solution before they are drawn. The sizing solution is a
mixture of binders, lubricants, and coupling and antistatic
agents; binders allow filaments to be packed in strands,
lubricants prevent abrasion of filaments, and coupling
agents give better adhesion between the inorganic glass
fiber and the organic matrix.
Fibers are then drawn into strands and wound on a
forming tube. Strands are groups of more than 204
filaments. The wound array of strands is then removed
and dried in an oven to remove any water or sizing
solutions.
The advantages of graphite fibers: high specific strength and modulus, low
coefficient of thermal expansion, & high fatigue strength. Graphite fibers are very
common in high-modulus and high-strength applications such as aircraft components
components,
etc.
Drawbacks: high cost, low impact resistance, and high electrical conductivity.
Manufacturing: Graphite fibers have been available since the late 1800s. However,
only since the early 1960s has the manufacturing of graphite fibers taken off. Graphite
fibers are generally manufactured from three precursor materials: rayon rayon,
polyacrylonitrile (PAN)
(PAN), and pitch
pitch. PAN is the most popular precursor.
Boron:
boron fibers are made by vapor depositing boron on a tungsten wire and coating the
boron with a thin layer of boron carbide.
Note: Why carbon or graphite fibers are produced very thin (far thinner than human
hairs), they can be woven into fabric. In contrast, The boron fibers due of its
manufacturing method are about the diameter of mechanical pencil lead, so they
cannot be bent or woven into fabric.
Specific Modulus and Specific Strength of Typical Fibers, Composites, and Bulk Metals
5.Matrix Materials:
Purpose:
-Support of the fibers or whiskers
-Protection of the fibers or whiskers
-Stress transfer between broken fibers or whiskers
Types:
1-Polymers
2-Metals
3-Ceramics
4-Carbon
Types:
Rubbers
Thermoplastics: Nylon, Polyethylene, Polycarbonate, Polypropylene (PP) &
Polysulfone
Thermosets
Thermosets:: Polyesters, Epoxy, Polyimide, Phenolic & …
Limitations:
low operating temperatures
high coefficients of thermal and moisture expansion
low elastic properties in certain directions.
Various polymers used in
advanced polymer composites:
The most common fibers used in Epoxy
PMCs: Phenolics
Glass Acrylic
Graphite Urethane
Kevlar Polyamide
Carbon
Islamic Azad University, Najafabad Branch 24
Introduction to Composite Materials
• Epoxies
Epoxies::
Epoxy resins are the most commonly used
resins. They are low molecular weight organic
liquids containing epoxide groups.
The advantages are high mechanical
strength and good adherence to metals and
glasses.
drawbacks are high cost and difficulty in
processing.
• Phenolics
Phenolics::
The advantages are low cost and high mechanical strength
Drawbacks include high void content.
• Polyesters
Polyesters::
The advantages are low cost and the ability to be made translucent;
Drawbacks include service temperatures below 170°F (77°C),
brittleness, and high shrinkage of as much as 8% during curing.
Although epoxy is costlier than other polymer matrices, it is the most popular PMC
matrix. More than two-thirds of the polymer matrices used in aerospace applications are
epoxy based.
The main reasons why epoxy is the most used polymer matrix material are:
• High strength
• Low viscosity and low flow rates, which allow good wetting of fibers and prevent
misalignment of fibers during processing
• Low volatility during cure
• Low shrink rates, which reduce the tendency of gaining large shear stresses of the
bond between epoxy and its reinforcement
• Available in more than 20 grades to meet specific property and processing
requirements.
Differences between
Thermosets &
Thermoplastics
Typical applications
of PMCs:
• Aircraft
• Space
• Sporting goods
• Medical devices
• Marine
Lamborghini
carbon-fiber reinforced plastics (CFRP) technology
used in:
•front frame structure
•exterior panels
•crash boxes
•major suspension components
•wheels and drive shaft
http://www.zerotohundred.com/
Compare polymer
properties with metals…
• Filament winding
(used generally for making pipes and tanks to handle chemicals)
-Wet winding
-Dry winding
• Pultrusion
• Wet/Hand lay up
• Autoclave forming
(used to make complex shapes and flat panels for structures in which low
void content and high quality are important)
Types:
Common matrix examples include Al, Mg, Ti, & Ni-Cr alloys
Question: Do any
properties degrade when
metals are reinforced with
fibers?
-Yes, it may reduce ductility
& fracture toughness…
Types:
Ceramic matrix composites (CMCs) have a ceramic matrix such as alumina,
SiC, Carbon, Mullite (Al2O3-SiO2) reinforced by fibers such as carbon or
silicon carbide.
Advantages:
High strength, Hardness, High service temperature limits for ceramics,
Chemical inertness, & Low density.
However, ceramics by
themselves have low fracture
toughness. Under tensile or
impact loading, they fail
catastrophically Reinforcing
ceramics with fibers, such as
silicon carbide or carbon,
increases their fracture
toughness.
Islamic Azad University, Najafabad Branch 33
Introduction to Composite Materials
Manufacturing techniques:
• CMCs can be cast from a molten slurry around stirred
stirred--in fibers with random
orientation or with preferred flow
flow--direction orientation
orientation..
• CMCs can be vapor deposited around a collection of already in in--place fibers
fibers..
• Plasma spraying
• Powder metallurgy methods
• Casting
• Diffusion welding
Applications:
• In high temperature areas in
which metal and polymer
matrix composites cannot be
used (thermal shields in space
vehicles, gas turbine, & etc)
• Cutting tool inserts in
oxidizing and high--
high
temperature environments
environments.. LAS: Lithium aluminosilicate, CAS: Calcium aluminosilicate
• Brake discs
• Slide bearings
Advantages:
1. They are lightweight – 1/3th the
density of metal: providing weight
reduction and thus, better fuel
efficiency.
2. They are durable and more heat
resistant than metals, requiring less
cooling air, and thereby improving
overall engine efficiency.
http://www.eng.fea.ru/FEA_news_600.html
Advantages:
Carbon is brittle and flaw sensitive like ceramics Reinforcement of a carbon
matrix allows the composite to fail gradually and also gives advantages such
as ability to withstand:
high temperatures
low creep at high temperatures,
low density
good tensile and compressive strengths
high fatigue resistance
high thermal conductivity Drawbacks:
high coefficient of friction high cost
low shear strength
oxidations at high temperatures
• Cermets are also used as nuclear reactor fuel elements and control
rods: Fuel elements can be uranium oxide particles in stainless steel
ceramic & boron carbide (B4C) in stainless steel is used for control rods.
Manufacturing techniques
techniques:: ?
Islamic Azad University, Najafabad Branch 39
Introduction to Composite Materials
Types:
Bimetals
Clad metals
Sandwich structures
Laminated fiber-reinforced composites
Clad Metals
Metals:: The cladding or sheathing of one metal with another is done to
obtain the best properties of both.
For example: high-strength Al alloys do not resist corrosion; however, pure
aluminum and some Al alloys are very corrosion resistant but relatively weak.
Thus, a high-strength aluminum alloy covered with a corrosion-resistant Al
alloy is a composite material with both high strength and corrosion
resistance.
Islamic Azad University, Najafabad Branch, A. Atrian 41
Introduction to Composite Materials
Sandwich Structures
Structures:: They’re 3-layered laminates consisting of thin facings
and a light-weight honeycomb or foam or … core.
turbine engines
Composite S-3A Spoiler
Applications:
• In aerospace & automotive industries
industries:: fuselage, energy absorption & …
• In laminated glass
glass::
Ordinary window glass: durable enough to retain its transparency under the extremes
of weather, brittle & dangerous when breaked.
-A plastic called polyvinyl butyral is very tough (deforms to high strains without
fracture), but is very flexible and susceptible to scratching.
-Safety glass is a layer of polyvinyl butryal sandwiched between two layers of
glass. The glass in the composite material protects the plastic from scratching and
gives it stiffness. The plastic provides the toughness of the composite material.
Fabric:
• Unidirectional
• Bidirectional: Plain, Twill, Satin, Basket, Leno
Powder Metallurgy:
• Spark plasma sintering (SPS)
• Selective laser sintering (SLS)
• Hot isostatic pressing (HIP)
• Hot pressing
• Hot extrusion
• Cold pressing and sintering
• Cold isostatic pressing (CIP)+sintering
Applications:
Aerospace
Thermal Shield
Sensor (FGPM)
Biomedical
1- Materials:
• Al7075 powder as the matrix (gas atomized, 100 um, irregular morphology)
• SiC as the reinforcing particles (average 50 nm, nearly spherical morphology)
Agglomeration
2- Processing
• mixing manually
• Suspending mixture in ethanol
• ultrasonic vibration for 30 min
• drying
SEM micrograph
Temperature effect
Isotropic: An isotropic body has material properties that are the same in
every direction at a point in the body, i.e., the properties are independent
of orientation at a point in the body.