Section 12 Composites Materials and Technologies

E Bayraktar, Supmeca-Paris, Paris, France

r 2016 Elsevier Inc. All rights reserved.

Introduction

In general meaning, composites are classified as a relatively new family of materials characterized by lighter weight and greater
strength than conventional materials. The research in processing of the composite materials for their applications in advanced
manufacturing engineering systems are ongoing. Today, new design considerations in modern technologies are completely dif-
ferent from conventional ones. For example, in conventional design considerations, lifetime of the materials is predicted as 106
numbers of cycles used in usual manufacturing engineering whereas in modern technologies, lifetime of the new materials-
composites such as high speed train, new aircraft design, aerospace applications, new gas turbines, etc. is predicted as 1010–1011 or
even more.
In classical meaning, composite materials as structural materials in engineering applications include metal matrix composites
(MMCs), polymer matrix composites (PMCs), ceramic based composites (CMCs), and also composite materials aimed for
building applications. Many composites used today are at the primary advantage of materials technology, with their performance
and costs suitable to ultra-challenging high technological applications. But heterogeneous materials combining the best char-
acteristics of dissimilar components have been used by nature for millions of years. Ancient society, reproducing nature, used this
approach as well. Very simple examples can be seen in the Book of Exodus that describes preparing the composites by ancient
society. Essentially, processing of composite materials is an art and science of producing metal or metallic powders, and using
them to make finished or semifinished products. For this reason, this particulate technology is probably the oldest processing
technique known to man. There are a number of archeological evidences, from Neolithic age and then from Egyptians, Roman,
and Greek civilizations to our modern age, to prove that the ancient man knew something about it. However, scientists accept that
modern age of composite materials and their processing began when engineers replaced the carbon filament in the Edison lamp.
These examples show us the importance of the composites in modern society and usage of high technologies in our daily life,
thanks to composites. More research is needed for developing composites to adapt to new demands of the modern technologies.
For this reason, composite technologies are fundamental for the development of manufacturing engineering applications. The
composite processing and its usage in industrial applications require interdisciplinary scientific knowledge related to the different
scientific domains such as physics, chemistry, electronics, computer science, and essentially materials science. Therefore, we have
tried to present a comprehensive work that can be used as a widespread reference by everybody requiring materials science and
manufacturing and interrelated scientific and technological information about the composites. It is required that the manu-
facturing engineers work with the materials designers – feedback coming basically from scientific research. If the composite design
can be intended carefully and the composite parts can be produced correctly, composite technologies will become much easier and
cheaper, and both the quality and evidently the reliability of the composite product can be improved.
As for the relation between matrix and reinforcement elements, a very interesting scientific history should be considered. All of
these outstanding aspects of the composites discussed above come from the relation and the behavior of the matrix continuous
phase and reinforcing and interface conditions between them when they are processed.
As is well known, the continuous phase is the matrix, which is a polymer, metal, or ceramic, etc. Polymers have low strength
and stiffness, metals have intermediate strength and stiffness but high ductility, and ceramics have high strength and stiffness but
are brittle. As a continuous phase, the matrix achieves numerous critical functions, including maintaining the fibers in the proper
direction and arrangement in space and protecting them from abrasion and the environment. Reinforcement elements can be
divided into three classes: particle reinforced, short fiber reinforced, and continuous fiber reinforced elements. Among these three
classes, the manufacturing cost of particulate reinforced MMCs is low, which makes it attractive and commercially viable to
consider for industrial applications.
In case of polymer and MMCs that have a strong bond between the fiber/reinforcement and the matrix, the matrix conveys
loads from the matrix to the fibers – reinforcements through shear loading at the interface. However, in ceramic matrix composites,
the main objective is to increase the toughness rather than the strength in regular way; therefore, a low interfacial strength bond is
required. Evidently, the type and quantity of the reinforcement determine the final properties. In summary, the reinforcements are
added into the matrix material in order to improve the mechanical properties of composites. On the other hand, the use of single
reinforcement in a matrix may occasionally affect the other mechanical as well as physical properties of the composites. In order to
overcome this difficulty, two reinforcements are principally added to the matrix material to produce the hybrid composites. As a
general rule, the smaller the diameter of the reinforcement/fiber, the higher its strength, but often the cost increases as the diameter
becomes smaller. In addition, smaller-diameter high-strength fibers have greater flexibility and are more amenable to manu-
facturing processes such as weaving or forming over radii. Typical fibers include glass, aramid, and carbon, which may be
continuous or discontinuous.

Reference Module in Materials Science and Materials Engineering doi:10.1016/B978-0-12-803581-8.04108-4 1

2 Section 12 Composites Materials and Technologies

As for MMCs, here, a typical example should be the aluminum metal matrix composites (AMMCs) that are being considered as
a group of new advanced materials for its light weight, high strength, low thermal expansion coefficient, and good wear resistance,
especially very huge reserve exists as row materials in the world. Aluminum matrix composites have been prepared very easily for
various applications in aeronautic-aerospace, automotive, military and electronic industry due to their exceptional properties. One
may indicate that MMCs adjust the best properties of the two components, such as ductility and toughness of the matrix and high
modulus and strength of the reinforcements. These clear and visible properties of these materials allow them to be the prospective
candidate for numerous applications such as automotive, aerospace and military, electronics industries, etc.
Additionally, processing of the MMCs can be of two types: solid state and liquid state processing. Solid state processing is
characteristically a powder metallurgy-based process, in which the matrix powder and reinforcement particles are mixed together
and compacted to form a bulk shape. Microstructure and final properties of solid state processing can be controlled very easily and
processed very economically when compared to liquid phase sintering. Many detailed information can be found in this volume
and many attractive and alternative technologies on the composites will be discussed in detail in different chapters of this volume.
Section 12 of Reference Module in Materials Science and Materials Engineering as a Comprehensive Materials Processing ‘Work’
edited by Professor Saleem Hashmi (the ‘Editor-in-Chief’) represents a comprehensive work for this series as a practical library and
scientific source which is dynamic in nature, being periodically updated, and it is arranged to meet the needs of the materials
science and manufacturing community.
There are about seven different basic levels containing different chapters which address general information and basic methods
of composite materials and composite technologies as an essential scientific area, outlined below:
In the 1st basic level, ‘General Classification of Composites’ is discussed and details of subbasic levels are as follows:
Composites-Overview, MMCs, Ceramic Matrix Composites (CMCs), PMCs, and Hybrid Composites.
In the 2nd basic level, ‘Microstructural Design of Composites,’ sublevels discussed are as follows: Effect of Microstructure
Variables (MMC–PMC–CMC–Hybrids), Type of Reinforcements and Matrices, Reinforcement Architecture, and Reinforcement/
Matrix Interface (bond strength).
In the 3rd basic level, ‘Production and Processing’ is discussed under three sublevels with different chapters: Powder Processing
Practice for MMCs, Powder Processing Practice for PMCs, and High-temperature Composites: Processing and Properties.
In the 4th basic level, ‘Manufacturing and Implementation of Composite Materials’ are discussed in general way as Manu-
facturing Process Selection for Composite Components and Joining of Composites.
In the 5th basic level, Design and Applications of Composites is discussed under five sublevels with different chapters as
follows: Composites in Automotive Applications: Design Concepts, Industrial Applications of Ceramic Matrix Composites,
Composites in Aeronautic and Aerospace Applications, Design Concepts Composite Applications Advanced Composites, and
Applications and Design Concepts for Railway-Train-High Speed Train.
In the 6th basic level, ‘Damage Analyses of Composite Structures’ is discussed with very rich chapters under the sublevels as
follows: Damage Analyses of MMCs, Damage Analyses of Ceramic Matrix Composites, Damage Analyses of PMCs, and Damage
Analyses of Hybrid Composites.
In the 7th basic level, ‘Novel Composites from Recycled Materials and Their Environmental Effects’ are discussed in the
following sublevels: Recycled MMCs. Recycled Ceramic Matrix Composites, and Recycled PMCs.

Concluding Remarks and Acknowledgment

This Section 12 presents a collection of very rich chapters related to aspects of general information and methods of composite
materials and composite technologies. Putting together a volume as a successful work of this scale is a skillful endeavor and could
not have been achieved without the contribution and hard work of the authors of the chapters of this volume. The editor conveys
his deep appreciation to all the authors and coauthors of the actual articles of this Section for their contribution in preparing their
individual subjects. Their hard work is gratefully acknowledged.
And finally, my deep and sincere acknowledgments to Professor Saleem Hashmi, the Editor-in-Chief of Reference Module in
Materials Science and Materials Engineering as a Comprehensive Materials Processing ‘Work’ for the role he has played as a driving
force to edit and help us to finish each Section. Special thanks are also to the coordinating staff members of ELSEVIER of this
massive work and to the ELSEVIER editorial staff.