Composite Engineers Viewpoint

Rik Heslehurst PhD, MEng, BEng(Aero)

FIEAust, FRAeS, CPEng

Composite Fibre Volume and Weight Ratios

In this article we look at the issue of volume ratio versus weight ratio in the design and
fabrication of composite structures. Are they not the same thing? What is the
relationship between volume ratios and weight ratios?

As the composites industry has grown there has become a bit of a divide between the
language of the composite design engineer and the composite fabricator. In particular
how each group describes the ratio of fibre to resin in the composite structure. The
design engineer refers to the fibre/resin ratio in terms of volume of fibres to volume of
resin. On the other hand, the composite fabricator will talk of the fibre/resin ratio in
terms of fibre-to-resin weight ratios in the composite structure. Are they not the same
thing? Well no they are not, but they are related. Each term has a very important
relationship to the engineer or fabricator and they are essential in their development of
the final composite component.

The discussion herein relates to wet resin lay-up techniques. Here the fabrication process
will wet out the fibres with a wet resin system, i.e. wet lay-up, resin infusion processes
and resin injection processes.

The basic engineering properties of a composite material can be determined by either
experimental stress analysis (testing) or theoretical mechanics (micromechanics). The
micromechanics approach utilises knowledge of the individual fibre and resin properties,
and the proportionality of fibres to the resin in the lamina. A rule of mixtures approach
can best be used to derive the majority of the composite lamina properties. For example
the lamina axial modulus is derived from:

E
x
= E
f
V
f
+ E
m
V
m

Where: E
f
is the fibre modulus of elasticity
E
m
is the matrix (resin) modulus of elasticity
V
f
is the fibre volume ratio
V
m
is the matrix volume ratio
V
f
+ V
m
= 1 with zero voids

When fabricating composite materials and structures from dry fibre (rovings or cloth
form) and pouring liquid resin onto the fibres, the correct ratio of weights of fibre and
resin are required. For example, the called-out ratio of say 60:40, requires a ratio of 60%
fibre weight to 40% resin weight.

This resin weight is measured out, poured over the fibre system and worked into the
fibres. This is referred to as wetting out the fibres.


FIBRE VOLUME AND WEIGHT RATIO RELATIONSHIP

While the fibre weight ratio is easily determined by simple weighing, the fibre volume
ratio is quite difficult to determine. Typically, an ASTM test method is employed which
requires destruction of a small sample. However, the determination of fibre volume ratio
can be derived from the fibre/resin weight ratio. The approach is as follows:

1. The fibre weight is based on the areal weight and a known or measured planar area.

2. After processing, the composite laminate weight is measured.

3. The resin weight is the difference between the composite and fibre weights:

W
resin
= W
composite
W
fibre


4. From vendor data we obtain the density of both the fibre and the resin systems. (If
not available from vendor data, the density can be determined experimentally.)

5. Now calculate the volume of the fibres in the composite:

fibre
fibre
fibre
W
V

=

6. Then determine the fibre/resin weight ratio and the fibre/resin density ratio.

7. Calculate the fibre/resin volume ratio:


resin
resin resin
fibre fibre
fibre
V W
V W

| |
| |
= |
|
|
\
\


8. Now determine the matrix volume ratio:

resin
1
1
m
fibre
V
V
V
=
| |
+
|
\


9. Finally, calculate the fibre volume ratio:
1
f m voids
V V V =

An example of the above is shown in the following extract of an excel spreadsheet. The
input data is shown in italics and the calculated results are underlined.



Excel Spreadsheet Extract to
Calculate Fibre Volume Ratio from Weight Fractions

Using the relationship established earlier, we can
estimate the required fibre-to-resin weight ratio for a
required fibre volume ratio. This will then give a more
reliable approach in achieving the required engineering
properties of the composite material. Rearranging the
earlier equations gives the following design expression:

So, for example, if the required fibre volume ratio is 60%, then using a glass fibre/epoxy
resin system with a density ratio of 2.0 requires a fibre/resin weight ratio of 75:25.
Whereas, using a carbon fibre/epoxy resin system with a density ratio of 1.425 requires a
fibre/resin weight ratio of 68:32. Finally, for an aramid fibre/ epoxy resin system with a
density ratio of 1.142 requires a fibre/resin weight ratio of 63:38.

To achieve appropriate structural performance for a composite material, the fibre volume
ratio plays a crucial role. The engineering designer uses the fibre volume ratio to derive
the lamina properties and thus after lamination, structural properties. But to achieve the
required fibre volume ratio in wet lay-up processes the fabricator requires the fibre
weight to resin weight ratio. This paper provides the mathematical expression that relates
fibre volume ratio to fibre weight ratio. The expression is dependent on the ratio of the
fibre and resin densities. This relationship clearly identifies the importance of low fibre
densities when compared with the resin density. A design chart is provided to assist
fabricators and engineers identify the required fibre weight for a design fibre volume
ratio.

In the next article we consider the impact of fabric composite stacking arrangements. Do
I nest or stack woven cloth? What is the impact on structural performance and
deformation behaviour? I also welcome questions, comments and your point of view.
Feel free to contact me via r.heslehurst@adfa.edu.au. I may publish your questions and
comments, and my response in future newsletter.

1
resin
1
1
1
fibre
f fibre
f
W
V
V

(
(
(
= +
(
| |
| |
(
|
|
|
(

\
\