Definition: Composites are a group of materials from from the mixture of metals, ceramics and/or polymers in such a way

that unusual combinations of properties are obtained. The major classes of composites are: - fibre reinforced polymer matrix composites (FRP) - fibre reinforced metal matrix composites (MMCs) - fibre reinforced ceramic matrix composites (CMCs) - hybrid composites By far, the most commonly used composite is FRP. MMCs are used sparingly and CMCs are used in high-temperature aircraft applications (eg. brakes, nose cones).

 FRP composites basically consist of fibres embedded in a polymer matrix. The fibres can be in the forms of short particles, whiskers or continuous fibres. The fibres are typically 7-15 m in diameter. The fibres provide the composite structures with their important engineering properties, such as stiffness, strength and fatigue resistance. The types of fibres used in aircraft composites are: - high modulus or high strength carbon (graphite) - Kevlar (Aramid) - E- and S-glass - Boron

Continuous Fibres Composites consist of a matrix phase & reinforcement phase The matrix phase is the continuous phase & the reinforcement phase contains dispersed particles.

Short Fibres/Whiskers

The functions are of the resin matrix are to: bind the fibres together into a solid material act as a load transfer medium between the fibres and resin protect the fibres from environmental effects such as moisture, chemical corrosion, oxidation, abrasion and impact, which can led to embrittlement and failure. The resin has a strong influence on: compressive properties transverse properties impact properties service operating temperature.

Main reasons for using composites: light-weight high specific stiffness & strength good to excellent fatigue resistance good formability into near net shaped complex structures tailored design to maximise structural performance radar absorbing properties (stealth)

 Sound damping

Thermal and electrical insulation Impact energy absorption Corrosion resistance

 Composites used in leisure & commercial marine craft. Main applications: - Canoes & kayaks - Jet skis - Lifeboats - Dinghies - Powerboats - Patrol boats - Yachts - Fishing Trawlers - Passenger Ferries - Structures for large ships Main reasons for using composites are: reduced weight: increased speed & reduced fuel consumption reduced corrosion improved vibration & noise damping.

Carbon/graphite fibres: Carbon fibres consist of 93-95% carbon. Graphite fibres consist of more than 95% carbon. Carbon fibres are ~8 m in diameter. Carbon/graphite fibres occur in three forms: High tensile strength fibres: = 2.41 GPa; E = 207 GPa High modulus fibres: = 1.38 GPa; E = 345 GPa Ultra high modulus fibres: = 1.03 GPa; E = 483 GPa Carbon fibres are expensive: AUD200-600 per kg.

2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.

Mohr,J.G. & Rowe,W.P. Fiberglass. van Nostrand Reinhold, New York (1978)

Kevlar is an organic molecular fibre made by DuPont. It is an extremely tough, bullet proof fibre that is used for personnel protection on military and armoured structures. The fibers are joined by van der Waals bonding between oxygen and hydrogen atoms on adjoining chains.

2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.

Sandwich - A composite material constructed of a lightweight, low-density material surrounded by dense, solid layers. The sandwich combines overall light weight with excellent stiffness.

2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.

Metallic laminates have a unique combination of - high specific strength, - high specific stiffness, - corrosion resistance, - fatigue resistance, - fracture toughness and - light-weight.

Two hybrid composites are ARALL and GLARE: ARALL consists of aluminium alloy sheet bonded to a ply of Kevlar (Aramid) reinforcing with an epoxy matrix. GLARE consists of aluminium alloy sheet bonded to a ply of glass reinforcing with an epoxy matrix.

Weak/Compliant

Strong/Stiff Weak/Compliant

density of fibres

density of matrix phase

Weak/Compliant

Strong/Stiff

Weak/Compliant

Composites are strong in fibre direction Composites are weak in transverse fibre
direction

What material properties determine the

strength in the two directions?

Consider a unidirectional composite (with all the fibres aligned in the same direction) loaded in uniaxial tension: The Youngs modulus in the fibre direction, E1, can be estimated using a rule-of-mixtures:

Ef >> Em Therefore for maximum stiffness you need high modulus fibres and a large amount of fibres.

Effect of volume fraction of fibres on Youngs modulus of two glass/polyester composites The two ways to increase Youngs modulus are: - Use high stiffness fibres - Maximise fibre volume content
Where does the curve cross the Y-axis?

The Youngs modulus in the transverse direction, E2, can be estimated using rule-of-mixtures:

Weak/Compliant

The in-plane tensile strength, 1, can be estimated : using rule-of-mixtures: :

1 f is the tensile strengths of fibres m is the tensile stress acting on the matrix when the fibres fail.
The equation shows that maximising the fibre strength and fibre content will increase composite strength

Other mechanical properties of unidirectional composite loaded in uniaxial tension can also be estimated using rule-of-mixtures: Poissons Ratio: In-plane Shear Modulus:

For a fibre volume fraction of 0.6, determine the density, modulus and transverse modulus and tensile strength of the boron fiber-aluminium composite.

Comment on the difference in values. Why are normal and transverse modulus so different? An example like this will guaranteed be in the exam!

Rule-of-mixtures can not be used to calculate all properties. It cannot be used to predict such properties as: - compressive strength - ductility - impact properties - fatigue properties - creep resistance

2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.

Effect of Fibre Orientation Stress-strain curves very different for different fibre orientations. Draw the stress-strain curve for 0 and 90 degree plies.

2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.

Fibres are wound on a frame (unidirectional) Resin is applied and rolled into fibres to ensure wetting

Mostly for aerospace applications, we can buy carbon/epoxy pre-preg. The resin is partially cured, with the final curing after lay-up undertaken in the autoclave.

Fibre breaks accumulate in composite. Fibres fail at different times due to varying strength. The matrix transfers the load between neighbouring fibres and around fibre breaks.

Figures from Hull, 1981, p.134

Onset of fibre buckling

Kinking of brittle fibres (Carbon)

Kinking of ductile fibres (Kevlar)

Figures from Hull, 1981, p.157

Cracking along fibre matrix interface (depends on bonding strength), crack development stable if other layers support it.

Figures from Hull, 1981, p.152

SEM pictures of crack growth in composite

Delamination commonly occurs when applying through-thickness stress or after impact damage. Composites should not be designed to carry through-thickness stress.
S. Feih, PhD thesis, Cambridge University, UK, 2001

Further Reading
DR Askeland, The Science & Engineering of Materials, Stanley Thomas (Publishers) Ltd, Chapter 17. D Hull, Introduction to Composite Materials, Cambridge Solid State Science Series, 1981 Internet has lots of good web-sites on engineering polymers.