Professional Documents
Culture Documents
Contents
Introduction………………………………………………………………………..2
Bibliography……………………………………………………………………...12
Page 1 of 12
Steve Goddard
Introduction
Page 2 of 12
Steve Goddard
Anisotropic Not isotropic. Exhibiting different properties when tested along axes
in different directions within the material.
Autoclave Closed vessel for applying fluid pressure, with or without heat, to an
enclosed object.
Page 3 of 12
Steve Goddard
Ply A single layer (or lamina) used to fabricate a laminate. Also, the
number of single yarns twisted together to form a plied yarn.
Page 4 of 12
Steve Goddard
Release agent An specially formulated material placed between the mold and
uncured resin/fiber (usually sprayed or painted on the mold surface)
to prevent permanent bonding between the two during cure and
facilitates demolding after cure.
Resin A solid or pseudo-solid polymeric material, often of high molecular
weight, which exhibits a tendency to flow when subjected to stress,
usually has a softening or melting range, and usually fractures
conchoidally. As composite matrices, resins bind together
reinforcement fibers and work with them to produce specified
performance properties.
Voids A void is a small fault with the composite component; the most
common are the micro voids. Larger voids in composites reduce
strength and could propagate under service loads producing
failures.
Page 5 of 12
Steve Goddard
These are materials which have spheres of the reinforcing material dispersed throughout the
matrix and can account for any desired volume of the composite.
Cermets or cemented carbides are examples of particle reinforced composites in which hard
ceramic particles are dispersed within a metal matrix. An example of this is cemented carbide
cutting tools eg. Tungsten carbide in a cobalt mix. By varying the amount of cobalt and the
size of the tungsten particles the properties, particularly the hardness and toughness of the
resulting composite can be controlled.
Many polymers incorporate particular fillers such as glass beads, silica flour and rubber
particles. Polystyrene is toughened by incorporating particles in the matrix to produce high
impact polystyrene.
Foams are a particular composite in which gas bubbles are bound by the matrix material. The
foam characteristics are governed by the density of the foam to that of the unfoamed matrix
and the cellular structure of the foam. The foam can be open cell, closed cell or a mixture of
the two. The gas bubbles in closed cell foams are not interconnected; Foams are used for
furniture cushions, energy absorbent packaging, thermal insulation and the filler material for
structural panels, these having skins covering the foam core.
The main functions of the fibers in a composite are to carry most of the applied loads to
provide stiffness which means that they should have a high tensile strength and a high elastic
modulus. The fibers used may be continuous, running the full length of the composite or
discontinuous i.e. In short lengths. They can be aligned so that they are in the same direction
or randomly orientated depending upon the directional properties required of the composite.
Some commonly used fiber reinforcing materials are alumina, silicon carbide (Nicalon), boron,
carbon, E-Glass, polyethylene (Spectra 1000) and polyamide (Aramid/Kevlar 49).
Structural
Structural composites such as laminates are composites in which materials are sandwiched
together to give a stronger laminated structure, plywood being an example. High performance
composite components consist of layers or laminae stacked in a predetermined arrangement.
A unidirectional lamina is often referred to as a ply and a stack of laminate is called a
laminate.
Page 6 of 12
Steve Goddard
These are the most common form of composite. Also know as FRP as mentioned above Fibre
Reinforced Polymers.
Increasingly found in the automotive industry, these materials use a metal such as aluminum
as the matrix, and reinforce it with fibres, or particles, such as silicon carbide.
Used in very high temperature environments, these materials use a ceramic as the matrix and
reinforce it with short fibres, or whiskers such as those made from silicon carbide and boron
nitride.
Page 7 of 12
Steve Goddard
Briefly the main functions and requirements of the matrix of a composite material are to:-
Picture 1 – S-Glass fibre woven cloth, ready for wet lay up.
Source: http://www.chinesemol.com/
Carbon Fibre
Page 8 of 12
Steve Goddard
Carbon Fibre is produced using a 3 stage process. And involves the use of heat, including the
stretching and oxidisation of the fibres resulting in high modulus, high strength carbon fibres.
Each carbon filament thread is a bundle of many thousand carbon filaments. A common
method for making carbon filaments is the oxidation and thermal pyrolysis of polyacrylonitrile
(PAN). The PAN is heated to 300 degrees C in air which breaks many of the hydrogen bonds
and oxidises the material, it is then placed into a furnace and heated to approximately 2000
degrees c which induces graphitization of the material which changes it molecular bond
structure.
Carbon Fibre
Source: https://www.ragingspeed.co.uk/
Kevlar
Page 9 of 12
Steve Goddard
Composite materials had been known in various forms throughout the history of mankind, the
history of modern composites probably began in 1937 when salesmen from the
Owens Corning Fiberglass Company began to sell fiberglass to interested parties around the
United States. Fiberglass had been made, almost by accident in 1930, when an engineer
became intrigued by a fiber that was formed during the process of applying lettering to a glass
milk bottle.
The initial products for this finely drawn molten glass were as insulation (glass wool) but
structural products soon followed.
It was then realized that the aircraft industry would be a likely customer for this new type of
material because the many small and vigorous aircraft companies seemed to be creating new
aircraft designs and innovative concepts in manufacturing almost daily with many of these
innovations requiring new materials.
The pace of composite development was accelerated during World War II. Not only were
even more aircraft being developed and, therefore, composites more widely used in
tooling, but the use of composites for structural and semi-structural parts was being explored
and then adopted. For example, during the war the last parts on an aircraft to be designed
were the ducts. Since all the other systems were already fixed, the ducts were required
to go around the other systems, often resulting in ducts that were twisting, turning and placed
in the most difficult locations. Metal ducts just couldn’t easily be made in these complicated
shapes. Composites were the answer. The composites were hand layed up on plaster
mandrels which were made in the required shape. Then, after the resin had cured, the plaster
mandrels were broken out of the composite parts.
Non-aircraft applications included cotton-phenolic ship bearings, asbestos4, phenolic
switchgears, cotton/asbestos-phenolic brake linings, cotton-acetate bayonet scabbards,
and thousands of others.
Many other composite improvements were developed during WWII including some innovative
manufacturing methods such as filament winding and spray-up. Sandwich structures using a
cellular core, fire resistant composites, and prepreg materials were also developed during this
time of development opportunity.
After the war focus was changed to anything that could be designed with composites,
manufacturers had to find new markets to apply their materials now that there was not so
much demand for aircraft parts.
The demand for automobiles seemed like the logical application for composites and by 1947
a fully composite body automobile had been made and tested. This car was reasonably
successful and led to the development of the Corvette in 1953.
One special use for composite materials was that of Convair Aircraft Company. The company
had thought that WWII pilots may want to continue their flying and also include families on
holidays. Convair developed a set of detachable wings which could be attached to a special
composite car; this allowed the driver to rent a wing assembly at one airport, fly to the
vacation site, turn in the wing assembly, and drive away. Prototypes were made and
successfully demonstrated.
Some of the products made during the post-war era have now emerged as major markets for
composite materials. These include tubs and shower assemblies, non-corrosive pipes,
appliance parts, trays, storage containers, and furniture.
Several innovative manufacturing methods were also developed in the late 1940's and early
1950's including pultrusion (by Goldsworthy), vacuum bag molding, and large-scale filament
winding.
In the 1950’s aerospace applications really pushed the advancement of composites, Richard
Young of the W. M. Kellogg Company began using filament winding for making small rocket
motors. This technology was purchased by Hercules and was the basis for the large-scale
rocket motor business which was at the heart of the space race.
In 1961 a patent was issued to A. Shindo for experimentally producing the first carbon
(graphite) fiber.
Page 10 of 12
Steve Goddard
New fibers were also introduced with boron filaments becoming available in 1965 and Aramid
fibers (Kevlar®) offered commercially by DuPont in 1971. Fibers made from ultra high
molecular weight polyethylene were made in the early 1970's. These advanced performance
fibers, along with fiberglass and carbon fibers, have led to tremendous developments in
aerospace, armour (structural and personal), sports equipment, medical devices, and many
other high performance applications. The development of new and improved resins has also
contributed to the expansion of the composites market, especially into higher temperature
applications and applications where high corrosion resistance is needed.
Today, the composites marketplace is widespread. As reported recently by the SPI
Composites Institute, the largest market is still in transportation (31%), but construction
(19.7%), marine (12.4%), electrical/electronic equipment (9.9%), consumer (5.8%), and
appliance/business equipment are also large markets. The aircraft/aerospace market
represents only 0.8% which is surprising seeing its importance in the origins of composites.
Page 11 of 12
Steve Goddard
Glossary
Bibliography
www.efunda.com
Lecture Notes
http://www.eurocomposites.com
www.pipexstructuralcomposites.co.uk
Page 12 of 12