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CM Module 1
CM Module 1
• Advantages
• High strength and stiffness
• Low weight ratio
• Material can be designed in addition to the structure
Applications
• Straw in clay construction by Egyptians
• Aerospace industry
• Sporting goods
• Automotive
• Construction
Types of Composites
Matrix Metal Ceramic Polymer
phase/Reinforc
ement Phase
Metal Powder metallurgy Cermets Brake pads
parts – combining (ceramic-metal
immiscible metals composite)
1. Aluminum
2. Mica
3. Glass
C. Flake Composites -3
• A laminate is a stack of
lamina arranged with their
main reinforcement in at least
two different directions.
E. Filled Composites
• Uses:
• high performance replacement for glass
fiber
• Examples
• Armor, protective clothing, industrial,
sporting goods
• Advantages:
• higher strength and lighter than glass
• More ductile than carbon
Fibers - Carbon
• 2nd most widely used fiber
• Examples
• aerospace, sporting goods
• Advantages
• high stiffness and strength
• Low density
• Intermediate cost
• Properties:
• Standard modulus: 207-240 Gpa
• Intermediate modulus: 240-340 GPa
• High modulus: 340-960 GPa
• Diameter: 5-8 microns, smaller than human hair
• Fibers grouped into tows or yarns of 2-12k fibers
Fibers -- Carbon (2)
• Types of carbon fiber
• vary in strength with processing
• Trade-off between strength and modulus
• Intermediate modulus
• PAN (Polyacrylonitrile)
• fiber precursor heated and stretched to align structure
and remove non-carbon material
• High modulus
• made from petroleum pitch precursor at lower cost
• much lower strength
Fibers - Others
• Boron
• High stiffness, very high cost
• Large diameter - 200 microns
• Good compressive strength
• Polyethylene - trade name: Spectra fiber
• Textile industry
• High strength
• Extremely light weight
• Low range of temperature usage
Fibers -- Others (2)
• Thermosets
• cure by chemical reaction
• Irreversible
• Examples
• Polyester, vinylester
• Most common, lower cost, solvent resistance
• Epoxy resins
• Superior performance, relatively costly
Matrices - Thermosets
•Polyester
Polyesters have good mechanical properties, electrical
properties and chemical resistance. Polyesters are
amenable to multiple fabrication techniques and are low
cost.
•Vinyl Esters
Vinyl Esters are similar to polyester in performance.
Vinyl esters have increased resistance to corrosive
environments as well as a high degree of moisture
resistance.
Matrices - Thermosets
•Epoxy
Epoxies have improved strength and stiffness properties
over polyesters. Epoxies offer excellent corrosion
resistance and resistance to solvents and alkalis. Cure
cycles are usually longer than polyesters, however no
by-products are produced.
☞ Lay–up
☞ Curing
A. Open–mold
(1) Hand lay–up
(2) Spray–up
(3) Vacuum–bag molding
(4) Pressure–bag molding
(5) Thermal expansion molding
(6) Autoclave molding
(7) Centrifugal casting
(8) Continuous pultrusion and pulforming.
1. Hand Lay-up
Hand lay–up, or contact molding, is the oldest and
simplest way of making fiberglass–resin composites.
Applications are standard wind turbine blades, boats,
etc.)
2. Spray-up
In Spray–up process, chopped fibers and resins are
sprayed simultaneously into or onto the mold. Applications
are lightly loaded structural panels, e.g. caravan bodies,
truck fairings, bathtubes, small boats, etc.
3. Vacuum-Bag Molding
The vacuum–bag process was developed for making
a variety of components, including relatively large
parts with complex shapes. Applications are large
cruising boats, racecar components, etc.
4. Pressure-Bag Molding
Pressure–bag process is virtually a mirror image of
vacuum–bag molding. Applications are sonar domes,
antenna housings, aircraft fairings, etc.
5. Thermal Expansion Molding
In Thermal Expansion Molding process, prepreg layers
are wrapped around rubber blocks, and then placed in
a metal mold. As the entire assembly is heated, the
rubber expands more than the metal, putting pressure
on the laminate. Complex shapes can be made
reducing the need for later joining and fastening
operations.
6. Autoclave Molding
Autoclave molding is similar to both vacuum–bag and
pressure–bag molding. Applications are lighter, faster and
more agile fighter aircraft, motor sport vehicles.
7. Centrifugal Casting
Centrifugal Casting is used to form round objects such as
pipes.
• Highly automated
• low manufacturing
costs if high
throughput
• e.g., Glass fiber pipe,
sailboard masts
Prepregs
compression
molding
vacuum bagging
Material Forms
• Textile forms
• Braiding or weaving
• Tubular braided form
• can be flattened and cut for non-tubular
products
Fabric Structures
• Pultrusion
• Fiber and matrix are pulled through a
die, like extrusion of metals --
assembles fibers, impregnates the
resin, shapes the product, and cures
the resin in one step.
• Example. Fishing rods
Pultrusion
Manufacturing