ME3400: INTRODUCTION TO

COMPOSITES

Fan Shi
2023 fall
Department of Mechanical and Aerospace Engineering
Course Introduction / Organization
▪ Course topics and schedule
▪ Course organization
▪ Objectives
▪ Learning outcomes
▪ Assessment
▪ Attendance

▪ Contacts of the instructors

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The instructors
▪ Course coordinator and lecturer:
▪ Assistant Prof. Fan Shi
▪ Office: 2544
▪ Email: maefanshi@ust.hk

▪ Teaching assistant
▪ Mr. Wuke XU
▪ Office: 2567
▪ Email: wuke.xu@connect.ust.hk

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Textbook

▪ I.M. Daniel and O. Ishai, Engineering Mechanics of

Composite Materials, 2nd, 2006 (Main textbook,
purchase from amazon.com)
Free online version: https://profs.basu.ac.ir/r-
seifi/free_space/composites.pdf

Other references:
▪ A.K. Kaw, Mechanics of Composite Materials, 2nd, 2005
▪ R.M. Jones, Mechanics of Composite Materials, 1999
▪ Textbooks of solid mechanics…

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Main textbook

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Course topics and schedule
Topics
• Introduction to composite (Chapter 1)
• Characteristics and types of composites
(Chapter 2)
• Review of solid mechanics (…)
• Micromechanics of lamina (Chapter 3)
• Macromechanics of lamina (Chapter 4)
• Strength and failure of lamina (Chapter 5)
• Experimental characterisation (Chapter 10)
• Inspection of composites (by myself)
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Schedule
Time
• Introduction to composite
• Characteristics and types 1st homework

• Review of solid mechanics

• Micromechanics of lamina 2nd homework

Lab sessions

Midterm exam
• Macromechanics of lamina
• Strength and failure of lamina
4th homework
• Experimental characterisation
• Inspection of composites

Final report/presentation
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Objectives

▪ Be familiar with the importance and mechanical

properties of modern composites.
▪ Learn the rule of mixture and how to analyse
elastic properties of a lamina.
▪ Deep understanding of anisotropy
▪ Understand the principle of strength and failure
of a lamina.
▪ Learn fundamental philosophies of inspecting
composite components

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Learning outcomes

▪ Students know basic concepts, types of common

composites.
▪ Students can predict the elastic constants,
strength, and possible modes of a unidirectional
lamina, given constituent properties and loading
conditions.
▪ Students can analyse strength and failure of a
typical unidirectional lamina.
▪ Students can apply the knowledge for designing
lamina
▪ Students know the basic methodologies to inspect
the structural integrity of composite materials.

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Course Assessments
▪ Homework:
(30%)
▪ Midterm exam:
(20%)
▪ Final project
(40%)
▪ Lab session:
Strength testing
(10%), held by Mr. Wuke XU
Additional Lab session:
Ultrasonic NDE of composite

Please finish by yourself!

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 Class policies
▪ Students are expected to attend and participate in all
scheduled classes, including lab sessions.
▪ In general, makeup exams will not be given.
▪ Academic Integrity - Any homework or exam handed in by an
individual must represent their own original work. It is the
responsibility of the student to refrain from infractions of
academic integrity, which includes cheating, fabrication and
plagiarism. Such infractions will be given no credit and will be
subject to penalties outlined by the University Code of
Conduct.
http://ugadmin.ust.hk/integrity/student-1.html

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Lab session
• Mechanical testing

You will participate the lab demonstration of

1. Mechanical testing of composite

2. Finish an online quiz.

Your grade will depend on attendance, self-

discipline during the lab session and the
online assessment.
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lab session
• Ultrasonic inspection of composite
• Defect detection and location.

You will participate the lab demonstration of

1. Ultrasonic inspection of composite

2. Detection and localization of possible

defects from measured signals

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About my research
Play with acoustics and ultrasound!
(Ultrasonics, Acoustics, Seismic waves etc.)

Very close collaborations with

aerospace, nuclear, oil/gas, and
energy sectors.
https://www.imperial.ac.uk/people/f.shi12
https://www.mae.ust.hk/en/people/faculty/detail/fan-shi

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ME3400: INTRODUCTION TO
COMPOSITES
Outline

▪ What are composite materials? (definition)

▪ Why use composite? (advantages)
▪ Typical examples of composites
▪ Industrial applications

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What are composite materials?
Definition:
A composite consists of two or more
physically distinct and mechanically
separable materials, which are combined to
give desirable overall properties.

Carbon Epoxy Carbon fiber

(Graphite) reinforced composite! 17
What are composite materials?

For an individual material, when

enhancing one property, the other
property will be weakened.

But when combined materials with

different properties, there will be an
improvement in both properties.

Composite!

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Why composite?
• The properties of a composite material are usually superior to
each of its constituent properties.
• It can fit the loading condition even if one of its constituent
would fail.
• It can be designed to satisfy certain need in engineering
where a single material cannot reach
• It meets the special requirements of thermal/electrical/
properties.

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Why composites?

▪ High specific strength (strength to density ratio)

▪ High specific stiffness (modulus to density ratio)
▪ Fatigue resistance
▪ Thermal stability
▪ Chemical (Corrosion) resistance
▪ Wear resistance
▪ Damping
▪ ……
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A video showing the history of using composites in aerospace industry

https://www.youtube.com/watch?v=wXxn-8OA8Ac
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 REINFORCEMENT
COMPOSITE = + MATRIX
+ INTERFACE
Reinforcement Matrix
▪ Discontinuous • Continuous
• Protective
▪ Strong/Stiff
• Weak
▪ Lightweight • Lightweight

Interface
• Reinforcement/matrix
bond, hold the two
• Strong or weak 22
 Reinforcement (Black)
Matrix (yellow)

Lamina (One single layer)

Interface between
reinforcement and matrix

Laminate (Multiple layers)

Composite can have various forms!

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An example of multi-layer structures:
Plywood

• Layup of thin wood

sheets with different
wood grain orientations

• Strength of the panel

consistent in all
directions
Multiple layers
• High quality and high
strength, low weight

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The use of plywood

‘Zhenghe’ ship for ‘The Wooden Wonder’

Expeditionary voyages to Southeast Asia Mosquito combat aircraft during world war II
Ming dynasty 1405 AD Royal Air Force

Ship size: 140m× 50m The fastest operational

aircraft in 1941 25
Can you come up with any
Examples of composites?

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Natural and man-made composites
Natural: Wood = Cellulose + Lignin
Bone = Bone-salt plates (Calcium)/
Phosphate ions + collagen

Traditional man-made:
Ancient wall = Straw + mud
Concrete = Aggregate [gravels, crushed
rocks, sand] + Cement Paste

Advanced man-made:
Fibreglass = Glass fiber + Resin
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 Composite Nature of Wood

Cross section
(across the grain) Longitudinal section
(along the grain)
Compare:

Width of human hair, 80 µm

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Gibson & Ashby, Cellular Solids 2nd ED, 1997
Egyptians 4000 BC
Laminated writing material from the papyrus
plant

https://www.wikihow.com/Make-Papyrus 29
Egyptians and Mesopotamian 1300 BC
Straw bricks

https://www.youtube.com/watch?v=00sS
yYg2VHI

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Modern concrete

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Advanced composites:
Glass fibre reinforced plastic (GFRP) Glass fibre reinforced concrete (GFRC)

Carbon fibre reinforced plastic (CFRP)

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Advanced composites:
Seismic durable
Composites

sandwich
structures

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Constitute materials: two phases

• Reinforcement: the reinforced phase that

is usually discontinuous, high in stiffness
and strength.

• Matrix: the continuous phase that is usually

light, but softer and weaker than the
reinforcement.

• Interface: the layer between reinforcement

and matrix that holds the two phase
together.
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Matrix materials Rolls Royce ultrafan

Matrix

• Main carrier of external loads

• It dominates the primary mechanical properties
and macroscope property of composite material
with low to medium performance.

Polymers Metals & Alloys Ceramics Carbon-Carbon

<400C 1100C 1600C

2000+C
https://www.youtube.com/watch?v=eoNySabChvA
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https://www.youtube.com/watch?v=auk-LRqtFs8
Reinforcements
Reinforcement
Inorganic Organic
▪ Glass • Aramid
▪ Carbon (Kevlar)
▪ SiC • Natural fibers
▪ Si3N4 • Polymers
▪ Alumina
▪ Boron
▪ Metal/Alloy

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Reinforcement

Reinforcement

• Light weight

• High stiffness and strength

• Sustainability to corrosion, elevated

temperature

• Functional degradation upon cyclic

loads
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Reinforcement materials

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Interface

The layer between reinforcement and matrix.

• It provides the bonding affinity between reinforce

phase and matrix, and transfer loads from matrix.
• The overall macroscopic strength and toughness of
the composite is closely related to interface.
• For fiber/matrix composites, interface is a
protection layer to prevent fiber from chemical
reaction

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Properties of reinforcement and matrix

Monolithic material

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Reinforcement types
Spherical
• Particle-reinforcement aspect ratio ~ 1
• Fiber-reinforcement
• Platelet-reinforcement

long and thin,

thin plate, aspect ratio ~ 10
Aspect ratio l1 ~ l2 >> l3 to 10n
Anisotropic
strengthening

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Classification of composite material systems

anisotropic

Quasi-
isotropic

Quasi-
isotropic

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Matrix Fiber Matrix material
Type
Polymer • E-glass • Epoxy
• S-glass • Phenolic
• Carbon (graphite) • Polyimide
• Aramid (Kevlar) • Bismaleimide
• Boron • Polyester
• Thermoplastics (PEEK,
polysulfone, etc.)
Metal • Boron • Aluminum
• Borsic (silicon • Magnesium
carbide coated • Titanium
boron fibers) • Copper
• Carbon (graphite)
• Silicon carbide
• Alumina
Ceramics • Alumina • Alumina
• Silicon carbide • Silicon carbide
• Silicon nitride • Silicon nitride
• Glass-ceramic
Carbon • Carbon • Carbon
Hybrid • All fibers • Modified polymer matrix + 43
metal sheets
 Specific strength

Epoxy

1040 Steel

Matrix
Specific strength

Aluminum

Wood

Glass/Epoxy
Composite

Carbon/Epoxy
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Applications of composites

▪ Aerospace
▪ Civil infrastructure
▪ Automobile
▪ Energy
▪ Marine
▪ Sports and recreation
▪ Biomedical
▪ Electronics
▪ ……
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Aerospace: Boeing 787

Composite by volume: 80%

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Aerospace: Airbus A380

Composite by weight: ~25% 47

Civil infrastructure

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Li-ion battery

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Energy

Length of 50m for a

typical wind turbine
blade

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And many other fields …

Glass fiber/Epoxy hull World lightest bike from IVW:

1260 grams CFRP frame and fork

Carbon fiber/PEEK
Hip prosthesis

Acer’s Ferrari 4000 carbon fiber NB

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