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For the specic carbon and glass ber based composite countertops. The most advanced examples perform roumaterials often referred to loosely as 'composites, see tinely on spacecraft and aircraft in demanding environFiber-reinforced polymer.
ments.
A composite material (also called a composition ma-
1 History
The earliest man-made composite materials were
straw and mud combined to form bricks for building
construction. Ancient brick-making was documented by
Egyptian tomb paintings.
Wattle and daub is one of the oldest man-made composite
materials, at over 6000 years old.[1] Concrete is also a
composite material, and is used more than any other manmade material in the world. As of 2006, about 7.5 billion
cubic metres of concrete are made each yearmore than
one cubic metre for every person on Earth.[2]
Composites are formed by combining materials together to form
an overall structure that is better than the sum of the individual
components
2 EXAMPLES
the 20th century, with some properties superior to
manufactured Portland cement.
Papier-mch, a composite of paper and glue, has
been used for hundreds of years
The rst articial bre reinforced plastic was
bakelite which dates to 1907, although natural polymers such as shellac predate it
Shape memory polymer composites are highperformance composites, formulated using bre or
fabric reinforcement and shape memory polymer resin as
the matrix. Since a shape memory polymer resin is used
as the matrix, these composites have the ability to be
easily manipulated into various congurations when they
are heated above their activation temperatures and will
exhibit high strength and stiness at lower temperatures.
They can also be reheated and reshaped repeatedly
without losing their material properties. These composites are ideal for applications such as lightweight, rigid,
deployable structures; rapid manufacturing; and dynamic
reinforcement.
High strain composites are another type of highperformance composites that are designed to perform in
a high deformation setting and are often used in deployable systems where structural exing is advantageous. Although high strain composites exhibit many similarities to
shape memory polymers, their performance is generally
dependent on the ber layout as opposed to the resin content of the matrix.
3
ceramic matrix composites (CMC), which includes bone
(hydroxyapatite reinforced with collagen bres), cermet
(ceramic and metal) and concrete. Ceramic matrix composites are built primarily for fracture toughness, not for
strength.
Organic matrix/ceramic aggregate composites include
asphalt concrete, mastic asphalt, mastic roller hybrid,
dental composite, syntactic foam and mother of pearl.
Chobham armour is a special type of composite armour
used in military applications.
Additionally, thermoplastic composite materials can be
formulated with specic metal powders resulting in materials with a density range from 2 g/cm to 11 g/cm (same
density as lead). The most common name for this type
of material is high gravity compound (HGC), although
lead replacement is also used. These materials can be
used in place of traditional materials such as aluminium,
stainless steel, brass, bronze, copper, lead, and even tungsten in weighting, balancing (for example, modifying the
centre of gravity of a tennis racquet), vibration damping,
and radiation shielding applications. High density composites are an economically viable option when certain
materials are deemed hazardous and are banned (such as
lead) or when secondary operations costs (such as machining, nishing, or coating) are a factor.
Pipes and ttings for various purpose like transportaA sandwich-structured composite is a special class of tion of potable water, re-ghting, irrigation, seawater,
composite material that is fabricated by attaching two desalinated water, chemical and industrial waste, and
thin but sti skins to a lightweight but thick core. The sewage are now manufactured in glass reinforced plastics.
core material is normally low strength material, but its
higher thickness provides the sandwich composite with
high bending stiness with overall low density.
Wood is a naturally occurring composite comprising
cellulose bres in a lignin and hemicellulose matrix.
Engineered wood includes a wide variety of dierent
products such as wood bre board, plywood, oriented
strand board, wood plastic composite (recycled wood bre in polyethylene matrix), Pykrete (sawdust in ice matrix), Plastic-impregnated or laminated paper or textiles,
Arborite, Formica (plastic) and Micarta. Other engineered laminate composites, such as Mallite, use a central
core of end grain balsa wood, bonded to surface skins of
light alloy or GRP. These generate low-weight, high rigidity materials.
2.2
Products
Fiber-reinforced composite materials have gained popularity (despite their generally high cost) in highperformance products that need to be lightweight,
yet strong enough to take harsh loading conditions
such as aerospace components (tails, wings, fuselages,
propellers), boat and scull hulls, bicycle frames and racing
car bodies. Other uses include shing rods, storage
tanks, swimming pool panels, and baseball bats. The
new Boeing 787 structure including the wings and fuselage is composed largely of composites. Composite ma-
3 Overview
4 CONSTITUENTS
Many commercially produced composites use a polymer
matrix material often called a resin solution. There are
many dierent polymers available depending upon the
starting raw ingredients. There are several broad categories, each with numerous variations. The most common are known as polyester, vinyl ester, epoxy, phenolic,
polyimide, polyamide, polypropylene, PEEK, and others. The reinforcement materials are often bres but also
commonly ground minerals. The various methods described below have been developed to reduce the resin
content of the nal product, or the bre content is increased. As a rule of thumb, lay up results in a product
containing 60% resin and 40% bre, whereas vacuum infusion gives a nal product with 40% resin and 60% ber
content. The strength of the product is greatly dependent
on this ratio.
Martin Hubbe and Lucian A Lucia consider Wood to
be a natural composite of cellulose bres in a matrix of
lignin.[4][5]
4 Constituents
4.1 Matrices
4.1.1 Resins
Typically, most common polymer-based composite materials, including berglass, carbon ber, and Kevlar, include at least two parts, the substrate and the resin.
Polyester resin tends to have yellowish tint, and is suitable for most backyard projects. Its weaknesses are that
it is UV sensitive and can tend to degrade over time, and
thus generally is also coated to help preserve it. It is often
used in the making of surfboards and for marine applications. Its hardener is a peroxide, often MEKP (methyl
ethyl ketone peroxide). When the peroxide is mixed with
the resin, it decomposes to generate free radicals, which
initiate the curing reaction. Hardeners in these systems
are commonly called catalysts, but since they do not reappear unchanged at the end of the reaction, they do not
t the strictest chemical denition of a catalyst.
Vinylester resin tends to have a purplish to bluish to
greenish tint. This resin has lower viscosity than polyester
Carbon ber composite part.
resin, and is more transparent. This resin is often billed
as being fuel resistant, but will melt in contact with gasoline. This resin tends to be more resistant over time to
the end-item design requirements. The principal factors degradation than polyester resin, and is more exible. It
impacting the methodology are the natures of the chosen uses the same hardeners as polyester resin (at a similar
matrix and reinforcement materials. Another important mix ratio) and the cost is approximately the same.
factor is the gross quantity of material to be produced.
Large quantities can be used to justify high capital expen- Epoxy resin is almost totally transparent when cured. In
ditures for rapid and automated manufacturing technol- the aerospace industry, epoxy is used as a structural maogy. Small production quantities are accommodated with trix material or as a structural glue.
lower capital expenditures but higher labour and tooling Shape memory polymer (SMP) resins have varying visual
characteristics depending on their formulation. These
costs at a correspondingly slower rate.
4.3
Cores
4.1.2
Other matrices
5
Fiber-reinforced composite materials can be divided into
two main categories normally referred to as short berreinforced materials and continuous ber-reinforced materials. Continuous reinforced materials will often constitute a layered or laminated structure. The woven and
continuous bre styles are typically available in a variety
of forms, being pre-impregnated with the given matrix
(resin), dry, uni-directional tapes of various widths, plain
weave, harness satins, braided, and stitched.
The short and long bers are typically employed in compression moulding and sheet moulding operations. These
come in the form of akes, chips, and random mate
(which can also be made from a continuous bre laid in
random fashion until the desired thickness of the ply /
laminate is achieved).
Common bers used for reinforcement include glass
bers, carbon bers, cellulose (wood/paper ber and
straw) and high strength polymers for example aramid.
Common matrices include mud (wattle and daub), cement (concrete), polymers (ber reinforced plastics),
metals and ceramics. Road surfaces are often made from
asphalt concrete which uses bitumen as a matrix. Unusual matrices such as ice are sometime proposed as in
pykecrete.
Concrete uses aggregate, and reinforced concrete additionally uses steel bars (rebar) to tension the concrete.
Steel mesh or wires are also used in some glass and plastic
products.
4.2
4.3 Cores
4.2.1
Reinforcements
Fiber
5 Fabrication methods
Fabrication of composite materials is accomplished by a
wide variety of techniques, including:
Dierences in the way the bers are laid out give dierent
strengths and ease of manufacture
5
Tufting
Z-pinning
FABRICATION METHODS
5.2
5.6
5.3
5.4
Autoclave moulding
5.5
5.7 Tooling
The mold and mold inserts are referred to as tooling. The mold/tooling can be constructed from a variety of materials. Tooling materials include invar, steel,
aluminium, reinforced silicone rubber, nickel, and carbon
ber. Selection of the tooling material is typically based
on, but not limited to, the coecient of thermal expansion, expected number of cycles, end item tolerance, desired or required surface condition, method of cure, glass
transition temperature of the material being moulded,
moulding method, matrix, cost and a variety of other considerations.
6 Physical properties
The physical properties of composite materials are generally not isotropic (independent of direction of applied
force) in nature, but rather are typically anisotropic (different depending on the direction of the applied force or
load). For instance, the stiness of a composite panel will
often depend upon the orientation of the applied forces
and/or moments. Panel stiness is also dependent on the
design of the panel. For instance, the bre reinforcement
and matrix used, the method of panel build, thermoset
versus thermoplastic, type of weave, and orientation of
bre axis to the primary force.
In contrast, isotropic materials (for example, aluminium
or steel), in standard wrought forms, typically have the
same stiness regardless of the directional orientation of
the applied forces and/or moments.
The relationship between forces/moments and
strains/curvatures for an isotropic material can be
described with the following material properties:
Youngs Modulus, the shear Modulus and the Poissons
ratio, in relatively simple mathematical relationships.
For the anisotropic material, it requires the mathematics
9 FURTHER READING
7 See also
Aluminium composite panel
American Composites Manufacturers Association
Chemical vapour inltration
Epoxy granite
Nanocomposites
Hybrid material
6.1
Failure
6.2
Testing
Composite laminates
Rule of mixtures
Void (composites)
8 References
[1] Shaer, G.D. An Archaeomagnetic Study of a Wattle and
Daub Building Collapse. Journal of Field Archaeology,
20, No. 1. Spring, 1993. 59-75. JSTOR. Accessed 28
January 2007
[2] Minerals commodity summary cement 2007. US
United States Geological Survey. 1 June 2007. Retrieved
16 January 2008.
[3] Heather Lechtman and Linn Hobbs Roman Concrete
and the Roman Architectural Revolution, Ceramics and
Civilization Volume 3: High Technology Ceramics: Past,
Present, Future, edited by W.D. Kingery and published
by the American Ceramics Society, 1986; and Vitruvius,
Book II:v,1; Book V:xii2
[4] http://www.ncsu.edu/bioresources/BioRes_02/BioRes_
02_4_534_535_Hubbe_L_BioResJ_Editorial_
LoveHate.pdf
[5] David Hon and Nobuo Shiraishi, eds. (2001) Wood and
cellulose chemistry, 2nd ed. (New York: Marcel Dekker),
p. 5 .
[6] Overview of key composite concepts.
[7] Waterman, Pamela J. The Life of Composite Materials.
Desktop Engineering Magazine. April 2007.
[8] Matzkanin, George A.; Yolken, H. Thomas. Techniques
for the Nondestructive Evaluation of Polymer Matrix
Composites (PDF). AMMTIAC Quarterly 2 (4).
9 Further reading
Robert M. Jones (1999). Mechanics of Composite Materials (2nd ed.). Taylor & Francis. ISBN
9781560327127.
Autar K. Kaw (2005). Mechanics of Composite Materials (2nd ed.). CRC. ISBN 0-8493-1343-0.
9
Handbook of Polymer Composites for Engineers By
Leonard Hollaway Published 1994 Woodhead Publishing
Matthews, F.L. & Rawlings, R.D. (1999). Composite Materials: Engineering and Science. Boca Raton:
CRC Press. ISBN 0-8493-0621-3.
10
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10
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