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Materials
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and Metallurgy
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(ME-209)
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IntroductionTJto Composites
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Dr. Tariq Jamil
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E-mail: tariqjamil@neduet.edu.pk
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Office: DICE Energy Lab, MED, NEDUET

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 Books / Resource Material
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• Text book: “Materials Science and Engineering: An Introduction” by

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David G. Rethwisch, 7th Edition
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• Chapter # 16

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• Reference book: Principles of Material Sciences & Engineering by
TJ William F. Smith,
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rd
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• Online resources
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• Lectures and resource material on Google classroom
• Check YouTube and Wikipedia for further information
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 Materials and Metallurgy (ME-209)
(According to Course Outline)
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Composites Introduction, Particle Reinforced Composites, Fiber Reinforced Composites,

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Processing of Composites, TJ TJ TJ

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 Chapter 16: Composite Materials
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• What are the classes and types of composites?

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• Why are composites used instead of metals, ceramics, or polymers?
• How do we estimate composite stiffness & strength?
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• What are some typical applications?
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 Composites
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• Combine materials with the objective of getting a more desirable

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combination of properties
• Ex: get flexibility & weight of a polymer plus the strength of a ceramic
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combined action TJ TJ TJ

• Mixture gives “averaged” properties

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 Application of Composite
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Terminology/Classification woven
• Composites:
fibers
-- Multiphase material with significant
proportions of each phase.
• Matrix:
-- The continuous phase 0.5 mm
-- Purpose is to:
cross
- transfer stress to other phases
section
- protect phases from environment view
-- Classification: MMC, CMC, PMC

metal ceramic polymer 0.5 mm

• Dispersed phase:
-- Purpose: enhance matrix properties.
MMC: increase σy, TS, creep resist.
CMC: increase Kc
PMC: increase E, σy, TS, creep resist.
-- Classification: Particle, fiber, structural
 Matrix and Disperse phase of composites

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 Composite Survey
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Composites

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Particle- Fiber-
Structural
reinforced reinforced
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Continuous Discontinuous TJ Sandwich TJ
Laminates
particle strengthened (aligned) (short) panels

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Randomly
Aligned
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oriented TJ
Composite Survey: Particle-I
Particle-reinforced Fiber-reinforced Structural
• Examples:
- Spheroidite matrix: particles:
steel ferrite (α) cementite
(ductile) (Fe3 C)
(brittle)
60 µm

- WC/Co matrix: particles:

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

- Automobile matrix: particles:

tires rubber C
(compliant) (stiffer)
0.75 µm
Composite Survey: Particle-II
Particle-reinforced Fiber-reinforced Structural

Concrete – gravel + sand + cement

- Why sand and gravel? Sand packs into gravel voids

Reinforced concrete - Reinforce with steel rod or remesh

- increases strength - even if cement matrix is cracked

Prestressed concrete - remesh under tension during setting of

concrete. Tension release puts concrete under compressive force
- Concrete much stronger under compression.
- Applied tension must exceed compressive force
Post tensioning – tighten nuts to put under tension threaded
rod

nut
Composite Survey: Particle-III

Particle-reinforced Fiber-reinforced Structural

• Elastic modulus, Ec, of composites:
-- two approaches.
upper limit: “rule of mixtures”
Ec = VmEm + VpEp
E(GPa)
Data: 350
lower limit:
Cu matrix 300
w/tungsten 250 1 Vm Vp
= +
particles 200 Ec Em Ep
150

0 20 40 60 80 10 0 vol% tungsten
(Cu) (W)
• Application to other properties:
-- Electrical conductivity, σe: Replace E in equations with σe.
-- Thermal conductivity, k: Replace E in equations with k.
Composite Survey: Fiber-I
Particle-reinforced Fiber-reinforced Structural
• Fibers very strong
– Provide significant strength improvement to
material
– Ex: fiber-glass
• Continuous glass filaments in a polymer matrix
• Strength due to fibers
• Polymer simply holds them in place
Composite Survey: Fiber-II
Particle-reinforced Fiber-reinforced Structural
• Fiber Materials
– Whiskers - Thin single crystals - large length to diameter ratio
• graphite, SiN, SiC
• high crystal perfection – extremely strong, strongest known
• very expensive
– Fibers
• polycrystalline or amorphous
• generally polymers or ceramics
• Ex: Al2O3 , Aramid, E-glass, Boron, UHMWPE
– Wires
• Metal – steel, Mo, W
 Fiber Alignment
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aligned aligned random
continuous discontinuous
Composite Survey: Fiber-III
Particle-reinforced Fiber-reinforced Structural
• Aligned Continuous fibers
• Examples:
-- Metal: γ'(Ni3Al)-α(Mo) -- Ceramic: Glass w/SiC fibers
by eutectic solidification. formed by glass slurry
Eglass = 76 GPa; ESiC = 400 GPa.
matrix: α (Mo) (ductile)

(a)
fracture
surface

2 µm
(b)
fibers: γ ’ (Ni3Al) (brittle)
Composite Survey: Fiber-IV
Particle-reinforced Fiber-reinforced Structural
• Discontinuous, random 2D fibers
• Example: Carbon-Carbon
C fibers:
-- process: fiber/pitch, then very stiff
burn out at up to 2500ºC. very strong
-- uses: disk brakes, gas (b)
C matrix:
turbine exhaust flaps, nose less stiff
cones. view onto plane less strong
fibers lie
(a) in plane
• Other variations:
-- Discontinuous, random 3D
-- Discontinuous, 1D
Composite Survey: Fiber-V
Particle-reinforced Fiber-reinforced Structural
• Critical fiber length for effective stiffening & strengthening:
fiber strength in tension fiber diameter
σf d
fiber length > 15 shear strength of
τc fiber-matrix interface
• Ex: For fiberglass, fiber length > 15 mm needed
• Why? Longer fibers carry stress more efficiently!
Shorter, thicker fiber: Longer, thinner fiber:
σd σf d
fiber length < 15 f fiber length > 15
τc τc
σ(x) σ(x)

Poorer fiber efficiency Better fiber efficiency

 Composite Strength:
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Longitudinal
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Continuous fibers - Estimate fiber-reinforced composite
strength for long continuous fibers in a matrix
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• Longitudinal deformation
σc = σmVm + σfVf but εc = εm = εf = ε
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volume fraction isostrain TJ TJ

∴ Eca = Em Vm + EfVf longitudinal (extensional)

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f = fiber
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matrix TJ
 Composite Strength:
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Transverse
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• In transverse loading the fibers carry less of the load -
isostress
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σc = σm = σf = σ εc= εmVm + εfVf

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∴
1 Vm Vf
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Ect E m Ef

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 Composite Production Methods-I
TJ • Pultrusion
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• Continuous fibers pulled through resin tank, then
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cure TJ TJ

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 Composite Production Methods-II
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• Ex: pressure tanks
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Composite Survey: Structural
Particle-reinforced Fiber-reinforced Structural
• Stacked and bonded fiber-reinforced sheets
-- stacking sequence: e.g., 0º/90º
-- benefit: balanced, in-plane stiffness

• Sandwich panels
-- low density, honeycomb core
-- benefit: small weight, large bending stiffness
face sheet
adhesive layer
honeycomb
Summary
• Composites are classified according to:
-- the matrix material (CMC, MMC, PMC)
-- the reinforcement geometry (particles, fibers, layers).
• Composites enhance matrix properties:
-- MMC: enhance σy, TS, creep performance
-- CMC: enhance Kc
-- PMC: enhance E, σy, TS, creep performance
• Particulate-reinforced:
-- Elastic modulus can be estimated.
-- Properties are isotropic.
• Fiber-reinforced:
-- Elastic modulus and TS can be estimated along fiber dir.
-- Properties can be isotropic or anisotropic.
• Structural:
-- Based on build-up of sandwiches in layered form.