Synthetic and Composite Materials Notes

• Synthetic materials- human-made substances that are designed and engineered to have
specific properties and characteristics
• Plastics - Defined as polymers of long carbon chains, capable of being molded or shaped,
usually by the application of heat and pressure.
(General Processes in making Synthetic Materials)

1. Polymerization- involves combining small molecules called monomers to form long chains
called polymers.

Two Methods of Polymerization Processes

a. Condensation polymerization - monomers are joined together by the elimination of a small

molecule, such as water or alcohol. Also known as dehydration synthesis.

b. Addition polymerization - monomers are joined together to form a polymer without the
elimination of any small molecules. Typically exothermic.
• 2. Extrusion- a process used to create long, continuous shapes from synthetic materials.
The material is melted and then forced through a die to create a specific shape or size.

3. Injection molding- the material is melted and injected into a mold, where it cools and
hardens to form the final product.

4. Compression molding- a pre-measured amount of resin is mixed with reinforcing

fibers and placed into a mold. The mold is then compressed and heated, causing the resin
to harden and form the final product.

5. Spinning- the material is melted and extruded through a spinneret, which creates long,
continuous fibers. E.g. Nylon and Polyester.

6. Coating- a process used to add a layer of material to the surface of a product.

• Properties of Synthetic Material

Strength and durability

• Resistance to environmental factors
• Customizability
• Low cost
 Plastic Materials are categorized into two groups:

1. Thermoplastic - is a type of plastic material that can be melted and reshaped multiple
times
2. Thermoset plastics- synthetic materials that undergo a permanent hardening process
after being exposed to heat and pressure once.

Examples of Plastics under Thermoplastic Examples of Plastics under Thermoset

• Epoxides- are commonly used in

• Arcylic- a substitute for glass in
coatings, adhesives, and electrical
applications where durability and weight
and electronic components. Also
are preferred
known as epoxy resins.
• PTFE is a type of thermoplastic that has
• Alkyds- commonly used in the
a high chemical resistance, non-stick
production of coatings and paints.
properties, heat resistance, and low
• Phenol-formaldehyde (Bakelite)- a
friction.
type of thermosetting plastic that
• Polythene- also known as polyethylene.
was first developed in the early
Produced from the monomer ethylene
1900s.
• Polyvinyl Chloride (PVC)- commonly
• Melamine-formaldehyde- commonly
found in products such as pipes
used in the production of
• Nylon- Silk like that has high resistance
kitchenware, laminates, and
to abrasion, chemicals, and moisture
adhesives.
used in ropes and cords.
• Urea-formaldehyde- commonly used
• Polystyrene- also known as styrofoam
in the production of kitchenware,
laminates, and adhesives.

• Composite Material- These materials are combined to produce a new material with
improved performance characteristics.
Examples of Composite Material:

1. Bone (Natural Composite) – contains protein collagen in mineral apatite.

2. Wood (Natural Composite) – contains cellulose in lignin.
3.Concrete (Artificial Composite) – contains aggregate and sand in cement.
4.Plywood (Artificial Composite) – has thin layers of wood that is glued together.
5.Reinforced (Artificial Composite) – contains steel or iron rods, plates, etc.
Two Essential Constituents of Composition:
1.) MATRIX – it should hold the reinforcement by strong bonding.

Types of Matrix

A.) Polymer Matrix – high processability

B.) Metal Matrix – high strength

C.) Ceramic Matrix – oxidation resistance

2.) REINFORCEMENT – it is the discontinuous phase and gives strength to the composite. It can
be:

3 Classification of Composites on the Basis of Reinforcement Material

A.) Particle Reinforcement-the discontinuous phase is in the form of particles suspended in

matrix. also called as particulate composites. Ex. Concrete

Divided into two categories:

i. Large Particle Reinforced Composite –major load is carried by them. (ex. Automobile Tires)

ii. Small Particle Reinforced Composites – nanosized particles that are added to the matrix (ex.
Thoria (ThO2)

B.) Fiber Reinforced Reinforcement - the dispersed or discontinuous phase or the

reinforcement is in the form of fibers. These are strong and sticky.

Divided into two categories:

i. Continuous Fiber Reinforced Composites (Long Fibers) – the fibers are long and continuous
in the matrix; and are layered parallel to each other
ii. Discontinuous Fiber Reinforced Composites (Short Fibers) - the fibers are short and
discountinuous. They may be aligned or randomly oriented.

C. Structural Composites - These composites are made by combining different materials with
different properties to create a composite material with improved overall performance.

Divided into two categories:

i. Laminar or Layered Composites – It consists of panels or sheets which are two dimensional.
(ex. Plywood)

ii. Sandwich Composites – low in strength

- material sandwich between 2 sheets

(ex. Polyvinylchloride)