Composites

Materials with a future

I. De Baere
2013-2014

Composites

Ives De Baere and Joris Degrieck 2013-2014

Use of material classes throughout the

centuries
Driving force for making materials choice:

costs of basic materials, production, use and end-of-life disposal

Composites

Ives De Baere and Joris Degrieck 2013-2014

Composites: what and why?

What do we understand under composites ?

(structural) materials consisting of clearly distinguishable phases

Heterogeneous materials !!

Why do we want to use composites ?

combine good properties of constituting materials

diminish effect of lesser properties
obtain new properties
try to achieve 1+1>2 !
Increase or decrease stiffness and/or strength; increase anisotropy
(orthotropy); increase compression properties or toughness; make it
cheaper, lighter, less or more electric or thermal conductive; improve
electromagnetic shielding; adapt coloring;

Composites

Ives De Baere and Joris Degrieck 2013-2014

Natural composites
Wood and bamboo
Bones and teeth
Horn

Composites

Ives De Baere and Joris Degrieck 2013-2014

Technical (manmade) composites

Ancient composites: dry clay or loam reinforced with
straw, plastered twigs, horse hair
Linnen in plaster
Layered
L
d wood
d
Artillery guns with layered barrel
Wood chipboard, triplex, multiplex
Steel reinforced concrete
./..

Composites

Ives De Baere and Joris Degrieck 2013-2014

Technical composites (2)

Fibre reinforced composites

Tyres of cars, airplanes,

Classical glass fibre reinforced
Classical
polyester (GFRP)
High end or high
performance composites

High end matrices (polymers, metals, ceramics) reinforced

with high end fibres (carbon fibres, aramid fibres, boron
fibres, SiC-fibres,)

Natural composites

( i h fibres
(with
fib
of
f fl
flax, h
hemp, jjute, b
bananas,))

Composites reinforced using carbon nanotubes

Nanocomposites in general
Composites

Ives De Baere and Joris Degrieck 2013-2014

Possible classification of composites

according to
reinforcing type

according to
composites
type
p
yp

Composites

Ives De Baere and Joris Degrieck 2013-2014

Fibre reinforced composites

Why use fibre reinforced materials ?
Fibre do have best shape for reinforcing
purposes: small diameter fibres show less faults,
fib
fibres
can h
have hi
higher
h stiffness
tiff
and
d strength
t
th in
i
fibre direction, fibres do have high specific
surface
Structural materials with high mechanical properties
(high stiffness and strength to weight ratio)
Resulting properties are typically (strongly) anisotropic!

Composites

Ives De Baere and Joris Degrieck 2013-2014

Fibre reinforced composites: constituents

reinforcing fibres
(mostly) determining for stiffness,
((mostly)
y) p
principal
p load bearing
g constituent,,
Reduces matrix crack propagation

matrix

responsible for transmission of load onto fibres,

keeps fibres together and in right place and direction,
protects fibres for the environment,
Reduces fracture of fibres

interface
typically consists of treatment or additional sizing of fibres
Protects fibres from damage (e.g. through abrasion) during handeling,
Promotes wetting of fibres with matrix,
Promotes or reduces bonding of fibres and matrix,
Is determining for transmission of stresses between fibres and matrix

Composites

Ives De Baere and Joris Degrieck 2013-2014

Principle types of fibres and matrices

Reinforcing fibres (3-200 m, mostly around 10 m)

Glass fibres
Carbon fibres
P l
Polymer
fibres
fib
Metallic fibres

carbon fibre

aramid fibre

glass fibre

Remark: Kevlar and Twaron are brand names for

aramid (from DuPont and AkzoNobel)

Matrices
Polymers: thermosetting & thermoplastic
Metals
Ceramics (e.g. glasses, carbon)
Composites

Ives De Baere and Joris Degrieck 2013-2014

Specific properties of reinforcing fibres

strength / specific mass

stiffness / specific mass

Composites

Ives De Baere and Joris Degrieck 2013-2014

History of technical fibre reinforced

composites

Composites

Ives De Baere and Joris Degrieck 2013-2014

History of technical fibre reinforced

composites
Motivation for development of composites
(early 1940s):
Military need for light and strong materials for
planes, boats, vehicles,
Fast developing plastics industry looking for new
markets, and for better mechanical
properties/behaviour of products from plastics
Discovery of (theoretically) extremely high
mechanical properties of materials with fibrous
shape (like glass fibre)
Composites

Ives De Baere and Joris Degrieck 2013-2014

History of technical fibre reinforced

composites (2)
1st generation (1940s & 1950s): glass fibre
reinforced plastics (GFRP)
2ndd generation (1960s): high performance
composites
3rd generation (1970s & 1980s): new markets,
synergy of properties
4th generation (1990s): smart composites,
nano composites, bio-mimic composites
Composites

Ives De Baere and Joris Degrieck 2013-2014

1st generation (1940s & 1950s)

Glass fibre reinforced plastics
Basic idea: (early) polymers with initially poor stiffness and
st
strength
th are reinforced
i f
d by
b fibres;
fib s ((early)
l ) st
strong and
d stiff
stiff, b
butt
very brittle glass fibres are protected by surrounding polymer
First glass fibres: Owens, 1932; mass production: 1935
Patent for polyester: 1936; epoxy: 1938
Marked by large dispersion of properties, brittle behaviour and
catastrophic failing

Composites

Ives De Baere and Joris Degrieck 2013-2014

1st generation (1940s & 1950s) (2)

First applications of glass fibre reinforced polymers in marine
applications (boats, 1940): light, strong, no corroding or rotting
Later on:

elektric ((switch)boards
)
((1942),
),
airplane parts(1943),

Landing in Normandie happend

to some extent with GFRP boats
(1944)
First use of prepreg
(pre impregnated fibre reinforcement)
(pre-impregnated
No talk yet of composites, but of Fibre Reinforced Plastics
(FRP)

Composites

Ives De Baere and Joris Degrieck 2013-2014

2nd generation (1960s)

High performance composites
First helicopter blades(Alouette II),
car bodies (Corvette),
(Corvette) printed circuit boards,
boards
gun barrels,
Start ofspace race: launching of Sputnik satellite (1957); call
for temperature resistant fibres and matrices: launching of
carbon, boron and ceramic fibres; use of metal matrices
Development of aramid fibre
(DuPont, 1971)
FromFRP towards Composites

Composites

Ives De Baere and Joris Degrieck 2013-2014

3rd generation (1970s & 1980s)

New markets, synergy of properties
Use of high performance composites for
civil applications,
c
app cat ons, ma
mainly
n y sports art
articles
c s and
an
vehicles
Metal matrix composites become
adult (with MIR, Skylab, Space
Shuttle): high strength at reasonable weight,
(very) high temperatures, low
thermal expansion coefficients
Ceramic matrix composites grow
through development of
SiC fibres

Composites

Ives De Baere and Joris Degrieck 2013-2014

3rd generation (1970s & 1980s) (2)

Synergy of properties and possibilities: mariage of material
specialists and designers results in new possibilities and new
applications
Optimal design of car bumper,
integrated in car body, and
allowing for optimal aerodynamic
behaviour

Development of sandwich
composites: thin, stiff and
composites
strong skins (of metal,
composites,) onto an extremely
light core (balsa, foam, honeycomb)

Composites

Ives De Baere and Joris Degrieck 2013-2014

Fibre reinforced composites today:

adult materials!
Civil engineering structures

Aeronautics and space

Maritime constructions

Automotive sector

Sports and recreation

Railway transport

Mechanical constructions

Composites

Ives De Baere and Joris Degrieck 2013-2014

10

4rd generation (1990s)

Smart composites, nano composites, biomimic composites
S
Smart composites
i
sense and
d react
to environment (e.g. through embedded
or intrinsic sensors and actuators)
Nano-composites have reinforcing phase with nano dimensions
(e.g. carbon nano tubes)
Bi
Bio-mimic
i i composites
i
i i
imitate
nature (e.g. self-healing
composites)

Composites

Ives De Baere and Joris Degrieck 2013-2014

Structures and components for fibre

reinforced polymers
typically consist from:

Laminates: thin plates or shells,

stacked
k d from
f
a number
b of
f llayers
Profiles
Massive components: typical for
small
m mechanical
m
components
mp
(e.g. small gears)
with an adequately chosen and
placed fibre pattern

Composites

Ives De Baere and Joris Degrieck 2013-2014

11

Laminates & fibre patterns

Polymer (matrix)

Reinforcing fibres (3-20 m)

Laminates

a) Isotropically
distributed short
fibres

b) Aligned long fibres

c) Fabric

Composites

Ives De Baere and Joris Degrieck 2013-2014

Fibre & reinforcing patterns

Short fibres (2 50 mm long); most often, fibres
are arranged in an in-plane isotropic pattern

mat

Composites

Ives De Baere and Joris Degrieck 2013-2014

12

Fibre & reinforcing patterns (2)

Unidirectionally aligned fibres
non-crimp fabric

Carbon pre-preg

Composites

Ives De Baere and Joris Degrieck 2013-2014

Fibre & reinforcing patterns (3)

Diverse textile patterns

fabrics
braidings
knittings

Composites

Ives De Baere and Joris Degrieck 2013-2014

13

Fibre & reinforcing patterns (4)

What is crimp?
crimp fabric

i >< shrinkage!
h i k
!
crimp

Composites

Ives De Baere and Joris Degrieck 2013-2014

Fibre & reinforcing patterns (5)

Winding patterns

Composites

Ives De Baere and Joris Degrieck 2013-2014

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Fibre & reinforcing patterns (6)

More-dimensional reinforcing patterns and preforms
3D-woven fabric
nD-preforms of
carbon
reinforced bars

Composites

Ives De Baere and Joris Degrieck 2013-2014

The stacking sequence of a laminate

Define:

- global structural axes (x, y, z)

- local axes of orthotropy (1,
(1 2,
2 3)
within each layer

- fibre direction of each layer.

Define the stacking sequence, e.g.:

0/0/45/ 45/ 45/45/0/0

0
0
45
-45
-45
45
0
0

02 / 45/ 45/ 02

02 / 45S
Composites

Ives De Baere and Joris Degrieck 2013-2014

15

Fabrication of fibre reinforced

polymer laminates: a typical example
thermosetting
polymer

glass
fabric

aramid
fabric

carbon
fabric

Fibre reinforcement

Composites

Ives De Baere and Joris Degrieck 2013-2014

Specific strength of some structural

materials
Strength/specific weight = length of suspended bar,
which just fails under its own weight

Compressive
strength

strength/specific price = strength of a bar of

1 m length and costing 1 BEF

Composites

Ives De Baere and Joris Degrieck 2013-2014

16

Composite properties
depend on:
properties of constituents (fibres, matrix)
fibre/reinforcing pattern (mat, UD, fabric,...) and stacking
sequence
fibre fraction, defined as:
fibre volume fraction (%): amount of fibres, relative to composite
volume; mostly used for design purposes and for estimation of
(mechanical) properties
fibre mass fraction (%): amount of fibres , relative to composite
mass; mostly used for fabrication purposes (ease of weighing)

Composites

Ives De Baere and Joris Degrieck 2013-2014

Influence of fibre fraction on matrix

stresses and strains
Transverse tensile test of ideal
composite with photo-elastic matrix
The fibres have nearly no deformation in
transverse direction; matrix has to
accommodate
d t f
for f
full
ll d
deformation
f
ti
Higher fibre fraction means less matrix
to take up global deformation

Stress concentrations in
matrix, lead to
accelerated onset and
growth of cracks

Composites

Ives De Baere and Joris Degrieck 2013-2014

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Laminates can equally

be hybrid, whereby two or more different
fibres (or matrices) are combined
Resulting laminates with higher stiffness, higher impact
resistance lower price,
resistance,
price

be laminated onto a core of wood, foam or

honeycomb to build a sandwich
Panels or shells with extremely
high bending stiffness and
strength compared to their
weight

Composites

Ives De Baere and Joris Degrieck 2013-2014

Sandwich panels

2t

t
weight
bending stiffness

1
1

4t
~1
12

balsa

~1
48

foam

Honeycomb
Corrugated

Composites

Ives De Baere and Joris Degrieck 2013-2014

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Sandwich panels

Composites

Ives De Baere and Joris Degrieck 2013-2014

Pros and cons of fibre reinforced materials

Main advantages of fibre reinforced polymers:
high ratios of stiffness and strength to specific mass
p
fast moving
g machines, sport
p
applications,...)
pp
(transport,
quite good corrosion resistance
complex geometries are possible. Optimal shaping is easier to
realise compared to e.g. use of metals

Composites

Ives De Baere and Joris Degrieck 2013-2014

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Pros and cons of fibre reinforced materials (2)

Main advantages of fibre reinforced polymers (2):

anisotropic stiffness and strength can be adapted to the

circumstances. "Tuning" of properties is possible to a large extent
(e g tuning of thermal expansion,)
(e.g.
expansion )

the number of connections can be drastically restricted

diverse advantages, such as:

electrically conductive or not,
thermally isolating or not,
absorption of vast amounts of kinetic energy

Composites

Ives De Baere and Joris Degrieck 2013-2014

Pros and cons of fibre reinforced materials (3)

Main disadvantages of fibre reinforced polymers:
price of the constituents (fibres, matrix,),
current production and processing methods are still (typically):
labour intensive; automation is often not straightforward,
slow (problem for series production),
quite to very expensive,

low fracture strains and low permanents strains are observed

(large plastic/permanent strains are desirable for lowering of
local stresses, and useful for energy absorption),

Composites

Ives De Baere and Joris Degrieck 2013-2014

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Pros and cons of fibre reinforced materials (4)

Main disadvantages of fibre reinforced polymers (2):

bonds are mostly difficult to realise, and are most often source of
serious problems

Typical impact
damage

sensitive to delaminations

limited possibilities for recycling (especially with thermosets).

(debonding of adjacent layers)

Composites

Ives De Baere and Joris Degrieck 2013-2014

Pros and cons of fibre reinforced materials (5)

Current obstacles for fibre reinforced polymers:
fibre reinforced materials differ to a large extent from isotropic
metals and p
polymers
y
concerning
g behaviour,, design
g and production
p
methods. They require conversion of personnel, specialised skills,
new facilities,...
a number of markets are
reticent to new materials
and/or products,
quite an amount of research is needed on:

on the fatigue behaviour, the impact behaviour, the influence of the

environment,...
on the development of new production techniques, and adequate and
cheaper design tools

Composites

Ives De Baere and Joris Degrieck 2013-2014

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