POLYMERIC COMPOSITES

DR.K. PANNEERSELVAM
COMPOSITE-DEFINITION

 A broad definition of composite is: Two or more chemically distinct

materials which when combined have improved properties over the
individual materials.

 The constituents retain their identities in the composite; that is, they
do not dissolve or otherwise merge completely into each other,
although they act in concert.
WHY COMPOSITES ARE IMPORTANT

 Composites can be very strong and stiff, yet very light in weight, so ratios of
strength‑to‑weight and stiffness‑to‑weight are several times greater than steel or
aluminum

 Fatigue properties are generally better than for common engineering metals

 Toughness is often greater too

 Composites can be designed that do not corrode like steel

 Possible to achieve combinations of properties not attainable with metals, ceramics, or

polymers alone
ADVANTAGES OF COMPOSITES
 Light in weight

 Strength-to-weight and Stiffness-to-weight are greater than steel or

aluminum

 Fatigue properties are better than common engineering metals

 Composites cannot corrode like steel

 Possible to achieve combinations of properties not attainable with metals,

ceramics, or polymers alone
COMPONENTS IN A COMPOSITE MATERIAL
 Nearly all composite materials consist of two phases:

1. Primary phase - forms the matrix within which the secondary phase is
imbedded

2. Secondary phase - imbedded phase sometimes referred to as a

reinforcing agent, because it usually serves to strengthen the
composite
 The reinforcing phase may be in the form of fibers, particles, or various
other geometries
FUNCTIONS OF THE MATRIX MATERIAL
(PRIMARY PHASE)

 Provides the bulk form of the part or product made of the composite

material

 Holds the imbedded phase in place, usually enclosing and often concealing it

 When a load is applied, the matrix shares the load with the secondary phase,

in some cases deforming so that the stress is essentially born by the

reinforcing agent
PROPERTIES OF A MATRIX

 Reduced moisture absorption

 Low shrinkage.

 Low coefficient of thermal expansion.

 Good flow characteristics so that it penetrates the fibre bundles completely

and eliminates voids during the compacting/curing process.

 Must be elastic to transfer load to fibres

PROPERTIES OF A MATRIX

 Reasonable strength, modulus and elongation (elongation should be greater than

fibre).

 Strength at elevated temperature (depending on application).

 Low temperature capability (depending on application).

 Excellent chemical resistance (depending on application).

 Should be easily processable into the final composite shape.

 Dimensional stability (maintains its shape).

THE REINFORCING PHASE (SECONDARY
PHASE)

 Function is to reinforce the primary phase

 Imbedded phase is most commonly one of the following shapes: –

 Fibers

 Particles

 Flakes
FACTORS IN
CREATING
COMPOSITES
 Matrix material
 Reinforcement material
 Concentration
 Size
 Shape
 Distribution
 Orientation
CLASSIFICATION
OF COMPOSITE-
BASE OF MATRIX
 Metal matrix composites
 Ceramic Matrix Composites
 Polymer Matrix Composites
 METAL MATRIX COMPOSITES

 Metals with low density and low temperature

toughness are preferred as matrix metal.

 Aluminum, titanium, magnesium and their alloys

Metal Reinforcement
 Advantages

 Higher operating temperatures Metal Matrix

 Non flammability and creep resistance

 Greater resistance to degradation by organic

SEM micrograph of Al2124 alloy and its MMC, showing distributions of 10wt.
fluids. %Al 2 O 3 particles in 2124 Aluminum alloy. (DOI: 
10.4028/www.scientific.net/AMM.232.39 )
APPLICATIONS OF MMC

 Aerospace application

 Gas turbine blades

 Electrical contacts
 CERAMIC MATRIX COMPOSITES

 Primary objective for developing CMCs was to

enhance the toughness while retaining the high
temperature properties.

 High melting points and good resistance to

oxidation
Ceramic Reinforcement
 But low tensile strength, impact resistant and
shock resistance SEM images of Mg-5 wt% CMC ( DOI:
http://dx.doi.org/10.3365/KJMM.2018.56.8.620)

 eg. Small particles of partially stabilized Zirconia

are dispersed within a matrix material Al2O3
PROPERTIES OF CMC

 Tensile & Compressive Behavior

 No sudden failure in CMC as like in Ceramics. Certain amount of Elongation in CMC improves
the tensile and compressive property.

 Fracture Toughness
 It limits to ceramics, but for CMC’s fracture toughness increases due to reinforcement.

 Fatigue Resistance
 Fatigue occurs due to cyclic loading, in case of CMC’s cracks arrested by reinforcement. So
higher Fatigue Resistance.
PROPERTIES OF CMC

 Thermal Response
 It can withstand high temperature.

 Chemical Inertness
 Ceramic do not react with chemicals
APPLICATIONS OF CMC

 Cutting Tools

 Aerospace

 Jet Engine

 Turbine Blades

 Hot fluid channels

POLYMER MATRIX COMPOSITES

 PMCs are the materials consisting of a polymer (resin) matrix combined

with a fibrous reinforcing dispersed phase..

 Commercially, PMCs are more important than MMCs or CMCs

 Low density, high specific strength, high specific stiffness, ease of

fabrication.

 Examples: Rubber reinforced with carbon black and fiber-reinforced

plastic (FRPs)
POLYMER MATRIX COMPOSITES

Polymer(Matrix) Composite (Matrix + Reinforcement)

(mycourses.aalto.fi)
POLYMER MATRIX COMPOSITES
 Reinforcements
 Principal load bearing member.

 Matrix
 provides a medium for binding and holding the reinforcements together
into a solid.
 protects the reinforcement from environmental degradation. \
 serves to transfer load from one insert (fibre, flake or particles) to the
other.
 Provides finish, colour, texture, durability and other functional properties.
 POLYMERS

 A polymer ( Greek poly-, "many" + -mer "part") is a large molecule, or macromolecule,

composed of many repeated subunits.

 Due to their broad range of properties, both synthetic and natural polymers play essential
and ubiquitous roles in everyday life.

 Polymers range from familiar synthetic plastics such as polystyrene to natural biopolymers
such as DNA and proteins that are fundamental to biological structure and function.

 Polymers, both natural and synthetic, are created via polymerization of many small
molecules, known as monomers
 CLASSIFICATION OF POLYMERS

 Linear polymer - Any polymer in which  Elastomers - These are polymers

molecules are in the form of chains. (thermoplastics or lightly cross-linked

thermosets) that have an elastic deformation
 Thermoplastic polymers - Linear or branched
> 200%.
polymers in which chains of molecules are
not interconnected to one another.

 Thermosetting polymers - Polymers that are

heavily cross-linked to produce a strong
three dimensional network structure.
MOLECULAR CHAIN CONFIGURATIONS:

 Linear

 Branched

 Crossed linked

 Network
 1. LINEAR POLYMERS

 The chainlike polymers shown in Fig are called linear polymers

because of their sequential structure.

 However, a linear molecule, not necessarily straight in shape.

 Generally, a polymer consists of more than one type of

structure; thus, a linear polymer may contain some branched
and cross-linked chains. As a result of branching and cross-
linking, the polymer’s properties are changed significantly.

 Some examples – polyethylene, Teflon, PVC, polypropylene

 BRANCHED POLYMERS:

 The properties of a polymer depend not only on the type of

monomers, but also on their arrangement in the molecular
structure. In branched polymers (Fig), side-branch chains are
attached to the main chain during the synthesis of the polymer.

 Branching interferes with the relative movement of the molecular

chains.

 As a result, their resistance to deformation and stress cracking is

increased.

 The density of branched polymers is lower than that of linear-chain

polymers, because the branches interfere with the packing
efficiency of polymer chains.
 CROSS LINKED POLYMERS

 Generally three-dimensional in structure, cross-linked

polymers have adjacent chains linked by covalent bonds.

 Polymers with a cross-linked structure are called

thermosets or thermosetting plastics; examples are
epoxies, phenolics, and silicones.

 Cross-linking has a major influence on the properties of

polymers (generally imparting hardness, strength,
stiffness, brittleness, .and better dimensional stability
NETWORK POLYMERS

 These polymers consist of spatial (three-dimensional)

networks of three or more active covalent bonds. A highly
cross-linked polymer also is considered a network polymer.
Examples: epoxies, phenol-formaldehyde polymers
MOLECULAR CHAIN CONFIGURATIONS

 Non crosslinked polymers

 Soften and melt at high temperature

 High toughness

 Low stiffness

 Crosslinked polymers
 Decompose at high temperature

 High stiffness

 High brittleness
THERMOSETS

 Thermoset materials are usually liquid or malleable prior to curing, and

designed to be molded into their final form.

 Thermoset materials are usually liquid or malleable prior to curing, and

designed to be molded into their final form.

 They develop a well-bonded three-dimensional structure upon curing.

Once hardened or cross-linked, they will decompose rather than melt.
THERMOSETS

 Thermoset materials are generally stronger than thermoplastic materials due

to this 3-D network of bonds, and are also better suited to high-temperature
applications up to the decomposition temperature of the material.

 Thermosets are made by mixing two components (a resin and a hardener)

which react and harden, either at room temperature or on heating.

 The resulting polymer is usually heavily cross-linked, so thermosets are also

called as network polymers.
THERMOSETS

 The cross-links form during the polymerisation of the liquid resin and
hardener, so the structure is almost always amorphous.

 On reheating the crosslinks prevent true melting or viscous flow so the

polymer cannot be hot-worked. Further heating just causes it to
decompose.
THERMOSETS

 Extensive cross-linking formed by covalent bonds.

 Bonds prevent chains moving relative to each other.
 TYPES OF
THERMOSETTING
PLASTICS
EPOXY

 Epoxy is a polymer that contain an epoxide group in its chemical

structure. Example: DGEBA (Diglcidyl Ether of Bisphenol A )

 Characteristics of Epoxy:
 Better Moisture Resistance

 • Low shrinkage

 Good adhersion with Reinforcement

 ADVANTAGES AND DISADVANTAGE OF
EPOXY RESIN

Advantages Disadvantage
 Good adherence to metal and glass fibers  Relatively high cost

 Curing agents, and modifiers are available  Long curing time

 Absence of volatile matters during curing

 Low shrinkage during curing

 Excellent resistance to chemicals and

solvents
APPLICATIONS OF EPOXY

 Paints and coatings

 Adhesives

 Industrial tooling and composites

 Wind Turbine Technology composites

 Electrical systems and electronics

 Marine applications

 Aerospace applications
POLYESTER

 A condensation reaction between a glycol and an unsaturated dibasic acid

results in polyester. This contains a double bond C=C between its carbon atoms.

 Characteristics of Polyester:
 Cheap

 Resistance to variety of chemicals

 Adequate moisture resistance

 Example: polyethylene terephthalate (PET)

 ADVANTAGES AND DISADVANTAGE OF
POLYESTER RESIN

Advantages Disadvantage
 Low cost  High shrinkage

 Low specific gravity  Strength and modulus are lesser than

epoxy
 Easy to handle

 Low viscous

 Ability to be made translucent

APPLICATIONS OF POLYESTER

 Making trays
 Shower stalls
 Boats
 Swimming pool
 Water tanks
ADVANTAGE OF THERMOSETS

High thermal High dimensional

High rigidity
stability stability

Resistance to creep
Light weight ( as High electrical and
and deformation
compare to metal) thermal insulation
under load
APPLICATION OF
THERMOSETS
THERMOPLASTICS

 In thermoplastic polymer, individual molecules are linear in structure

with no chemical linking between them.

 They are held in place by weak secondary bond (intermolecular

force), such as van der Walls bonds and hydrogen.

 Some thermoplastics normally do not crystallize, they are termed

as"amorphous" plastics and are useful at temperatures below the Tg.
THERMOPLASTICS

 No cross links between chains.

 Weak attractive forces between chains broken by warming.
 Change shape - can be remolded.
 Weak forces reform in new shape when cold.
REASONS FOR THE USE OF
THERMOPLASTIC MATRIX COMPOSITES

 Parts can be made and joined by heating.

 Parts can be remolded, and any scrap can be recycled.

 Thermoplastics have better toughness and impact resistance than

thermosets.

 Shorter fabrication time.

 Can be recycled.
 UNIQUE CHARACTERISTIC OF
THERMOPLASTIC
 Near to glass transition temperature Tg , polymeric materials changes a hard solid to soft,
tough ( leather like) solid. Over a temperature range around Tg .Near this temperature, the
materials is also highly viscoelastic.

 When load is applied it exhibit Elastic deformation.

 With increasing temperature polymer changes into rubberlike solid undergoing

deformation on external load.

 Further increasing the temp both amorphous and semicrystallline thermoplastic achieve
highly viscous state and attain the melting temp Tm .
TYPES OF
THERMOPLASTICS
LIMITATIONS OF PMC

 Low maximum working temperature.

 High coefficient of thermal expansion- dimensional instability

 Sensitivity to radiation and moisture.

 Processing temperature are generally higher than those with

thermosets.
APPLICATIONS OF PMCS

 Aircraft and aerospace applications

 Automotive applications

 Marine applications

 Sporting industries

 Biomaterials

 Industrial applications
CLASSIFICATION
BASED ON FIBERS

 There are five basic

types of composite
materials: Fiber,
particle, flake, laminar
or layered and filled
composites.
FIBER COMPOSITES

 In fiber composites, the fibers reinforce

along the line of their length. Reinforcement
may be mainly 1-D, 2-D or 3-D. Figure shows
the three basic types of fiber orientation.
 1-D gives maximum strength in one direction.

 2-D gives strength in two directions.

 Isotropic gives strength equally in all

directions.
 GLASS FIBER

 Glass fibers are manufactured from molten glass,

from which glass monofilaments are drawn and then
gathered to strands.

 The strands are used for preparation of different glass

fiber products (yarns, rovings, woven fabrics, mats).

 Fiberglass materials usually have laminate structure

with different fibers orientations in the reinforcing
glass layers.

 Various glass fibers orientations result in anisotropy of

the material properties in the plane parallel to the
laminates.
TYPES OF GLASS FIBER

 E-Glass: - the most popular and inexpensive. The designation letter “E” means
“electrical implies that it is an electrical insulator”. The composition of E-glass
ranges from 52-56% SiO2, 12-16% A1203, 16-25% CaO, and 8-13% B203.

 S-Glass: – stronger than E-Glass fibers (the letter “S” means strength). High-
strength glass is generally known as S-type glass in the United States, R-glass in
Europe, and T-glass in Japan. S-Glass is used in military applications and in
aerospace. S-Glass consists of silica (SiO2), magnesia (MgO), alumina (Al2O3 ).
TYPES OF GLASS FIBER

 C-Glass: – corrosion and chemical resistant glass fibers. To protect against water
erosion, a moisture-resistant coating such as a silane compound is coated onto
the fibers during manufacturing. Adding resin during composite formation
provides additional protection. C-Glass fibers are used for manufacturing storage
tanks, pipes, and other chemical resistant equipment.
ADVANTAGE OF GLASS FIBER

 High strength-to-weight ratio

 High modulus of elasticity-to-weight ratio

 Good corrosion resistance

 Good insulating properties

 Low thermal resistance (as compared to metals and ceramics).

APPLICATION OF GLASS FIBER

 Fiberglass materials are used for manufacturing: boat hulls and marine structures,

automobile and truck body panels, pressure vessels, aircraft wings and fuselage

sections, housings for radar systems, swimming pools, welding helmets, roofs,

pipes.
CARBON FIBER

 A carbon fiber is a long, thin strand of material about 0.0002-

0.0004 in (0.005-0.010 mm) in diameter and composed mostly
of carbon atoms.

 The carbon atoms are bonded together in microscopic crystals

that are aligned parallel to the long axis of the fiber. The
crystal alignment makes the fiber incredibly strong for its size.

 Several thousand carbon fibers are twisted together to form a

yarn, which may be used by itself or woven into a fabric.
TYPES OF CARBON FIBERS

 UHM (ultra-high modulus): Modulus of elasticity > 450GPa.

 HM (high modulus): Modulus of elasticity is in the range 350-450GPa.

 IM (intermediate modulus): Modulus of elasticity is in the range 200-350GPa.

 HT (high tensile, low modulus): Tensile strength > 3 GPa, modulus of elasticity <
100 GPa.

 SHT (super high tensile):  Tensile strength > 4.5GPa.

ADVANTAGE OF CARBON FIBER

 Light weight.
 High strength-to-weight ratio.
 Very High modulus elasticity-to-weight ratio.
 High Fatigue strength.
 Good corrosion resistance.
 Very low coefficient of thermal expansion.
 Low impact resistance.
 High electric conductivity.
 High cost.
APPLICATION OF CARBON FIBER

 Carbon Fiber Reinforced Polymers (CFRP) are used for manufacturing: automotive

marine and aerospace parts, sport goods (golf clubs, skis, tennis racquets, fishing

rods), bicycle frames.

KEVLAR FIBER

 Kevlar is the trade name (registered by DuPont Co.)

of aramid (poly-para-phenylene terephthalamide)
fibers.

 Kevlar fibers were originally developed as a

replacement of steel in automotive tires.

 Kevlar filaments are produced by extrusion of the

precursor through a spinneret.
TYPES OF KEVLAR FIBER

 Kevlar 29 – high strength, low density fibers used for manufacturing bulletproof
vests, composite armor reinforcement, helmets, ropes, cables, asbestos replacing
parts.

 Kevlar 49 – high modulus, high strength, low density fibers used in aerospace,
automotive and marine applications.

 Kevlar 149 – ultra high modulus, high strength, low density, highly crystalline
fibers used as reinforcing dispersed phase for composite aircraft components.
ADVANTAGE OF KEVLAR FIBER

 High modulus of elasticity. High Fracture Toughness (impact

resistance);
 Very low elongation up to breaking point.
High cut resistance.
 Low weight.
Textile processability.
 High chemical inertness. Flame resistance.

 Very low coefficient of thermal expansion.

DISADVANTAGE OF KEVLAR FIBER

 Absorb moisture (making Kevlar composites more sensitive to the

environment),

 Difficulties in cutting (Toughness makes fabrics difficult to cut with

conventional methods)

 Low compressive strength.

APPLICATION OF KEVLAR FIBERS

 Kevlar use in armor, military, and ballistic applications, like helmets and
bullet-proof vests.
 NATURAL
FIBERS
 Natural fibers are also called biofibers
or biofillers or Green reinforcement
materials. Principally, green
reinforcement materials are derived
from plant and animal-based biomas.

 The main objective to use natural

fibers as a reinforcement phase in
composites is to improve the
mechanical properties and production
of lightweight materials.
COMPARISON WITH
GLASS FIBER

 Replacing the glass fibers with

natural fibers is an added benefit
for the automobile industry due
to their low density and high
fiber diameter, which can
increase the tensile strength
using low filler content and
producing lightweight materials.
 PARTICULATE COMPOSITES
 A composite that consists of tiny particles of
one material embedded in another material.

 The particulates can be very small particles (<

0.25 microns), chopped fibers (such as glass),
platelets, hollow spheres, or new materials such
as bucky balls or carbon nano-tubes.

 They provide reinforcement to the matrix

material thereby strengthening the material.
The combination of reinforcement and matrix
can provide for very specific material properties.
ADVANTAGES OF PARTICULATE
COMPOSITES

 Provide reinforcement to the matrix  High toughness

material
 High tensile strength at elevated
 Improved material properties temperatures

 Tailored material properties  High strength to weight ratio (low density

high tensile strength)
 Manufacturing flexibility

 High creep resistance

APPLICATIONS OF PARTICULATE
COMPOSITES

 Appliances, toys, electrical products, computer housings, cell phone

casings, office furniture, helmets, etc. are made from particulate reinforced
plastics.

 Glass reinforced plastics are used in many automotive applications

including body panels, bumpers, dashboards, and intake manifolds.

 Brakes are made of particulate composite composed of carbon or ceramics

particulates.
APPLICATIONS OF PARTICULATE
COMPOSITES

 Ceramets contain hard ceramic particles dispersed in a metallic matrix. Eg.:

tungsten carbide (WC) or titanium carbide (TiC) embedded cobalt or nickel used
to make cutting tools.

 Widely used for automotive applications including pistons

 Concrete is cement strengthened by adding particulates.

 Reinforced rubber is obtained by strengthening with 20-50 nm carbon-black

particles. Used in auto tires.
 WHISKERS

 Single crystals grown with nearly zero defects are termed

whiskers.

 They are usually discontinuous and short fibers of different cross

sections made from several materials like graphite, silicon carbide,
copper, iron etc.

 Typical lengths are in 3 to 55 nm ranges.

 Whiskers can have extraordinary strengths up to 7000 mega

pascal.
ADVANTAGE OF WHISKERS

 Ceramic material’s whiskers have high moduli, useful strengths and low
densities.

 Specific strength and specific modulus are very high, and this makes ceramic
whiskers suitable for low weight structure composites.

 It also resist temperature, mechanical damage and oxidation more responsive

than metallic whiskers, which are denser than ceramic whiskers.
COMPARISON OF PROPERTIES
OF WHISKERS WITH OTHER
REINFORCEMENT MATERIALS
SELECTING THE REINFORCEMENTS

 The compatibility, density, chemical and thermal stability of the reinforcement with
matrix material is important for material fabrication as well as end application.

 Thermal expansion properties of matrix and reinforcement is an important

parameter for composites used in thermal cycling application.

 In particulate and whisker reinforced Composites, the matrix is the major load
bearing constituent.

 In continuous fiber reinforced Composites, the reinforcement is the principal load-

bearing constituent.
SELECTING THE REINFORCEMENTS

 In continuous fiber reinforced Composites, the reinforcement is the principal load-

bearing constituent.