Unit - I

Composite Materials (C)

 Lecture 6
Types of Composites
 Properties of composites in comparison
with standard materials

• Corrosion resistance 
• Inherent durability 
• Lightweight  
• High strength 
• Part Consolidation
Composite Survey
Com posites

Particle-reinforced Fiber-reinforced Structural

Large- Dispersion- Continuous Discontinuous Lam inates Sandwich

particle strengthened (aligned) (short) panels

A ligned Random ly
oriented
Classification of Composite Materials
by Matrix:
• Ceramic matrix composites (CMC):

– Silicon carbide-silicon carbide (SiC-SiC)

– Same material both matrix and filler BUT filler
different form such as whickers, chopped fibers or
strands to achieve preferred properties.
 Hybrid Composites

Incorporation of two or more fibres within a single

matrix resulted in formation of hybrid composite.
Hybrids: configuration

a b c

d e f
 HYBRID COMPOSITES
Hybrid materials are composites consisting of two
constituents at the nanometer or molecular level.
Commonly one of these compounds is inorganic and
the other one organic in nature.
Thus, they differ from traditional composites where
the constituents are at the macroscopic (micrometer
to millimeter) level. Mixing at the microscopic scale
leads to a more homogeneous material that either
show characteristics in between the two original
phases or even new properties.
Classification:
Hybrid materials can be classified based on
the possible interactions connecting the
inorganic and organic species.
Class I hybrid materials are those that
show weak interactions between the two
phases, such as van der Waals,
hydrogen bonding or weak electrostatic
interactions.
Class II hybrid materials are those that
show strong chemical interactions between
the components such as covalent bonds.
Advantages of hybrid materials over traditional composites

•Inorganic clusters or nanoparticles with specific optical,

electronic or magnetic properties can be incorporated in
organic polymer matrices.

•Contrary to pure solid state inorganic materials that often

require a high temperature treatment for their processing,
hybrid materials show a more polymer-like handling, either
because of their large organic content or because of the
formation of crosslinked inorganic networks from small
molecular precursors just like in polymerization reactions.
 Structural Composites

The properties of structural composites depend on

Constituents
Geometrical design
 Types of Structural Composites

Laminar: Is composed of two-dimensional sheets or panels that

have a preferred high strength direction such as is found in wood and
continuous and aligned fiber-reinforced plastics. The layers are
stacked and cemented together such that the orientation of the high-
strength direction varies with each successive layer. One example of a
relatively complex structure is modern ski and another example is
plywood.
 Structural Composites:

Sandwich Panels: Consist of two strong outer sheets which are

called face sheets and may be made of aluminum alloys, fiber
reinforced plastics, titanium alloys, steel. Face sheets carry most
of the loading and stresses.
Core may be a honeycomb structure which has less density than
the face sheets and resists perpendicular stresses and provides
shear rigidity. Sandwich panels can be used in variety of
applications which include roofs, floors, walls of buildings and in
aircraft, for wings, fuselage and tailplane skins.
 Applications of HYBRID COMPOSITES
•Scratch-resistant coatings with hydrophobic or anti-fogging properties.
•Nanocomposite based devices for electronic and optoelectronic applications
including light-emitting diodes, photodiodes, solar cells, gas sensors and
field effect transistors.
•Fire retardant materials for construction industry.
•Nanocomposite based dental filling materials.
•Composite electrolyte materials for applications such as solid-state lithium batteries
or supercapacitors.
•Corrosion protection
 Another Classification of Composite Materials
1. Metal Matrix Composites (MMCs) ‑ mixtures of ceramics and metals, such
as cemented carbides and other cermets

2. Ceramic Matrix Composites (CMCs) ‑ Al2O3 and SiC imbedded with fibers to
improve properties, especially in high temperature applications
The least common composite matrix

3. Polymer Matrix Composites (PMCs) ‑ thermosetting resins are widely used

in PMCs
Examples: epoxy and polyester with fiber reinforcement, and phenolic
with powders
 Metal Matrix Composites (MMCs)
A metal matrix reinforced by a second phase.

Reinforcing phases:

1. Particles of ceramic (these MMCs are commonly called cermets)

2. Fibers of various materials: other metals, ceramics, carbon, and boron
• Metal matrix composites (MMC):
– Metal matrix: Al, Mg, Fe, Cu, Ni
– Different metal or another material, such as a
ceramic or organic compound
– Example: Al-SiC (silicon carbide)
– Example: Al-Al2O3 (aluminum oxide)
High strength, high stiffness, dimensional stability,
high temperature and toughness.
Composition:
• MMCs are made by dispersing a reinforcing material into a metal
matrix.
•The reinforcement surface can be coated to prevent a chemical reaction
with the matrix.
•For example, carbon fiber are commonly used in aluminium matrix to
synthesize composites showing low density and high strength. However,
carbon reacts with aluminium to generate a brittle and water-soluble
compound Al4C3 on the surface of the fibre.
•To prevent this reaction, the carbon fibres are coated with nickel or
titanium boride.
Advantages of Composites
1. A higher performance for a given weight leads to fuel savings. Excellent strength-to-weight and
stiffness-to-weight ratios can be achieved by composite materials. This is usually expressed as strength
divided by density and stiffness density. These are so-called “specific” strength and “specific modulus)
divided by modulus characteristics.
2. Laminate patterns and ply buildup in a part can be tailored to give the required mechanical
properties in various directions.
3. It is easier to achieve smooth aerodynamic profiles for drag reduction. Complex double curvature
parts with a Smooth surface finish can be made in one manufacturing operation.
4. Part count is reduced.
5. Production cost is reduced. Composites may be made by a wide range of processes.
6 Composites offer excellent resistance to corrosion, chemical attack, and outdoor weathering;
however, some chemicals are damaging to composites (e.g. ,paint stripper),and new types of paint and
stripper are being developed to deal with this. Some thermoplastics are not very resistant to some
solvents. Check the data sheets for each type
Disadvantages of Composites
1. Composites are more brittle than wrought metals and thus are more easily damaged. Cast metals also
tend to be brittle.

2. Repair introduces new problems, for the following reasons: Materials require refrigerated transport and
storage and have limited shelf lives. Hot curing is necessary in many cases, requiring special equipment.

Curing either hot or cold takes time. The job is not finished when the last rivet has been installed.

3. If rivets have been used and must be removed, this presents problems of removal without causing
further damage.

4. Repair at the original cure temperature requires tooling and pressure.

5. Composites must be thoroughly cleaned of all contamination before repair.

6. Composites must be dried before repair because all resin matrices and some fibers absorb moisture.
 Natural Fiber Reinforcement
Composite

It is a type of Fiber Reinforced Composite, in which natural fibers are dispersed
into a polymer matrix.
They are renewable, cheap, completely or partially recyclable and biodegradable.
Natural fibers are incorporated into a matrix material such as thermosetting
plastics, thermoplastics or biopolymers.
Natural fibers being eco-friendly, lightweight, strong, and low cost have already
started to replace glass fibers in numerous engineering applications in automobiles,
furniture, packaging, and construction etc.
 What Is Natural Fiber ?

All fibres which come from natural sources (like plant, animal, etc.) are
called as natural fibers.
Natural fibres are greatly elongated substances produced by plants and
animals.
Lignocellulosic natural fibres are an excellent raw materials for production
of wide range of composites for different applications.
Classification Of
Natural Fibers
 Difference Between Natural Fiber And Synthetic Fiber
Natural Fiber
All of the natural fibers come from the nature
Fibers are found in staple or filament form
Length of the fiber is nature given
It is not possible to change in fiber structure
Comparatively less durable then synthetic
fibers
These are environment friendly
Use of natural fibers are limited then synthetic
fiber
Growth with its natural colors
Synthetic Fiber
These are completely man made
It is found in filament form
Length of the fiber is controlled by man
It is easy to change in fiber structure
These are more durable then natural fibers
Some fiber are harmful for the environment
These are used in multi task then natural fiber
Colors are added in solution bath as required
Classification Of
Polymer Matrix
 Advantages

Renewable
Recyclable
Eco-friendly
Light weight
Low cost
Acceptable specific strength properties
Better wear protection
They display acoustic insulation and absorb vibrations and large
quantities of energy when subjected to destruction.
Reaction to fire of composites based on natural fibres is much
more beneficial comparing to polymers
 Disadvantages

Moisture absorption, which causes swelling of the fibres.

These are UV-sensitive.
Lower durability.
Low impact strength
Fibre degradation during processing.
Fibre treatments can improve this considerably.
 Applications

Automobiles
Furniture
Packaging
Construction
Electronic Component
Marine
Aerospace
Consumer products
The main drivers for use of natural-fiber
based composites in automotive
applications
Demands for lightweight parts, which leads to a lowering in fuel
consumption
Acceptable mechanical properties, good acoustic properties.
Good recycling possibilities of the components made with thermoplastic
polymers, reducing the waste disposal problem
Technical benefits such as lower energy loss, longer lifetime of tools, better
wear protection etc. can be converted into cost saving potential.
Competitive pricing- Automotive industries have developed using
composites with non-wood fibers such as flax and hemp, as well as
cellulosics, as an alternative to fiber glass. The resultant composites are
lighter, and the natural fibers used by the car industry (VW/Audi, BMW) to
produce interior door panels, parcel shelves, dashboards, etc., are
competitively priced compared with fiberglass
 Natural Fiber Based Composite
In Automobile Industries
Flax fiber composite
Hemp fiber composite
Jute fiber composite
Kenaf fiber composite
Sisal fiber composite
Mechanical properties of natural fibres
compared with glass fiber
 Processing Of NFRC

Injection moulding
Compression moulding
Extrusion
Vacuum moulding
Pultrusion etc.