Professional Documents
Culture Documents
Protection of material surface Surface engineering Ex: Glasses, oxides, carbides, silicides, borides, nitrides
T. Udomphol
www.camcoat.u-net.com
Chapter 1
Porcelain enamel
Ceramic glaze
Glass enamel
October 2007
Chapter 1
Chapter 1
T. Udomphol
Microstructure of WC/10Co4Cr coating Thermal spraying of tungsten carbide-cobalt chromium coating (WC/10Co4Cr) on to a roll for the paper manufacturing industry
Suranaree University of Technology October 2007
Chapter 1
T. Udomphol
www.ijs.si/ctp/tin.jpg
October 2007
Chapter 1
Solar cell
http://www.energy.go.th
T. Udomphol
Doped with B, Al
Doped with P
P-N junction
October 2007
Chapter 1
Co-Cr alloy femoral head with high strength polyethylene cup (metal on polymer) Replaced by alumina (ceramic on ceramic) to reduce wear particle formation which causing loosening of the prostheses.
T. Udomphol
Various component for total hip prostheses including the stem with an alumina femoral head, and alumina AC cup, and a metal base for the AC cup
October 2007
Chapter 1
Bone joint
T. Udomphol
October 2007
Chapter 1
T. Udomphol
Artificial root which supports tooth replacement and crown (porcelain). Titanium is also a good candidate due to low modulus of elasticity and biocompatibility.
Chapter 1
Tissue surrounding the implant dies Biologically inactive Thin fibrous tissue forms around the implant Bioactive Interfacial bond between the bone and the prosthesis forms Resorption (Dissolving) The surrounding tissue replaces the implant material or portions of it.
Suranaree University of Technology October 2007
Chapter 1
Improving toughness ?
Ex: TiO2 (< 40 m) 98% theorectical density after 700oC sintering for 2 h.
T. Udomphol
October 2007
Chapter 2
composite materials
T. Udomphol
www.umms.sav.sk
October 2007
Chapter 2
composite materials
Structural materials can be mainly divided into four categories: metals, ceramics, polymers and composites.
Structural material made of two or more different materials in a macroscopic level. A structure or an entity made up of distinct components. A complex material, such as wood or fiberglass, in which two or more distinct, structurally complementary substances, especially metals, ceramics, glasses, and polymers, combine to produce structural or functional properties not present in any individual component.
October 2007
Chapter 2
composite materials
Natural forms Artificial forms
T. Udomphol
October 2007
Chapter 2
composite materials
Polymer Composites Resin Composites Cement Composites
Glass Composites
PMCs
T. Udomphol
CMCs
Composites
Al Composites Ti Composites
Other
Wood Composites
MMCs
Carbon Composites Ni based alloy Composites
Mg Composites
Steel Composites
October 2007
Chapter 2
composite materials
Applications
T. Udomphol
Chapter 2
Matrix
Metals Ceramics Polymers Wood
Reinforcing materials
Fibres Filament Particulates Flakes Globular Platelet Needles Woven Honey comb
October 2007
Chapter 2
www.millipore.com
http://en.wikipedia.org
Chapter 2
October 2007
Chapter 2
1) 2) 3) 4) 5)
Carbon fibres Boron nitride fibres Glass fibres Organic fibres Silicon carbide fibres
CVD monofilaments PCS multifilaments Whiskers
T. Udomphol
7) Nylon
October 2007
Chapter 2
T. Udomphol
Tensile strength
Schematic structure of carbon fibres
Suranaree University of Technology
Chapter 2
T. Udomphol
Glass fibres
Most are silica (SiO2) with addition of Ca, Na, B, Al, Fe. Can be divided into electrical, corrosion and strength glass.
Suranaree University of Technology
www.fiber-tensioners.com
Chapter 2
The raw materials are melted in a reservoir and fed into a series of platinum bushings, each of which has several hundred holes in its base. The glass flows under gravity and fine filaments are drawn mechanically downward onto a Continuous E-glass fibre production drum (at speed 2000-3000 m/min).
T. Udomphol
October 2007
Chapter 2
Whiskers Strongest reinforcing materials available Defect free, single crystal rods. 0.1-1.0 m in diameter and 5-100 m.
iar-ira.nrc-cnrc.gc.ca
1) 2) 3) 4)
fb6www.uni-paderborn.de
Chapter 2
T. Udomphol
The gas dissociates thermally at the fibre surface to deposit the SiC. Deposition of the second layer (graphite or diamond) is subsequently applied in the second reaction chamber to improve the effects of interaction reactions with matrices such as titanium.
Suranaree University of Technology
Chapter 2
Nylon
Refractory Alumina and alumiosilicate fibres can be divided into multifilaments (FTTM fibre) or short fibres (SaffilTM fibre).
Suranaree University of Technology
Nylon is a thermoplastic polymer (polyamine) and generally used for many applications. Strong, elastic and has abrasive resistance.
October 2007
Chapter 2
T. Udomphol
October 2007
Chapter 2
T. Udomphol
Carbides
Silicon carbide (SiC) Tungsten carbide (WC) Titanium carbide (TiC) Titanium boride (TiB2)
Borides
Nitrides
October 2007
Chapter 2
Choices of matrices
Matrix holds reinforcing material together and also determine the physical properties of the end products. Metals
T. Udomphol
Polymers
Plastics or resins are the most widely used. Lightweight. Easily fabrication. Low-moderate temperatures. Low-moderate strength and stiffness. Also used for reinforcing materials.
Ceramics
Cements are the most widely used. Light-moderate weight. High temperatures. High strength and stiffness but low toughness. Fabrication is not too difficult. Also used for reinforcing materials.
October 2007
Moderate to high temperatures. High strength stiffness, moderate toughness. Moderate weight. Difficult to fabricate. Also used for reinforcing materials.
Chapter 2
Choices of matrices
T. Udomphol
Specific strength of advanced materials. Maximum service temperatures for different kinds of materials.
Suranaree University of Technology October 2007
Chapter 2
T. Udomphol
October 2007
Chapter 2
Matrices -Polymers
The most widely used due to cheap fabrication (low temp ~ 300-400oC). Lightweight applications such as aircraft, sporting goods, wheelchairs Normally use carbon fibres as reinforcing materials.
T. Udomphol
Thermosets: epoxy resin*, phenolic resin or furfuryl resin Heat+pressure polymerization with cross-link Thermoplastics: polyimide (PI), Polyethersulfone (PES), polyetheretherketone (PEEK), polyetherimide (PEI) and polyphenyl sulfide (PPS). Lower temp + better plasticity
Suranaree University of Technology
injection moulding
October 2007
Chapter 2
Matrices -Ceramics
Ceramic matrix composites
Concrete (cement) Cermet (ceramic and metal) Bone (hydroxyapatite reinforced with collagen fibres)
T. Udomphol
Note:
Chapter 2
Matrices -Ceramics
enpub.fulton.asu.edu
Cement matrix composite Concrete is the most widely used civil structural materials.
CaO, MgO, SiO2 , Al2O3
T. Udomphol
Cement Sand
Curing (Hydration)
Gravel Admixture
Fine particulate such as silica (SiO2) fume or polymer such as latex to decrease porosity. Short fibres such as glass, steel, carbon
October 2007
Chapter 2
Matrices -Ceramics
Cermet
Cermet = ceramic (cer) and ~ <20% metallic (met) materials with Ni, Mo, Co as binders for oxides, boride, carbide or alumina High temperature resistance and hardness.
T. Udomphol
Ex: Spark plugs for internal combustion engine, composed of a shell, insulator (aluminium oxide) and conductor (Cu, Ni-Fe, Cr).
Spark plug http://en.wiki
pedia.org
Chapter 2
Matrices -Carbon
Carbon-carbon composites
Highly-ordered graphite fibres embedded in carbon matrix..
T. Udomphol
http://www.composites-bydesign.com
Strength and toughness superior to conventional graphite. Stiffer, stronger and lighter than steels or other metals. C-C composites consist of two brittle phases but are very tough. Oxidation problem at T > 320oC. required SiC coating or glassy sealant
C-C composite
C + O2 CO2
Suranaree University of Technology
Chapter 2
Matrices -Metals
ewkmmc.tuwien.ac.at
T. Udomphol
Aluminium alloys Magnesium alloys Titanium alloys Nickel base alloys Steels Copper alloys
October 2007
Chapter 2
T. Udomphol
www.duragear.com
Chapter 2
Mechanics of composites
How many fibres we can put in to improve strength? Volume fraction of fibres Fibre arrangement
T. Udomphol
V f max = 0.907
Chapter 2
Mechanics of composites
Longitudinal stress and stiffness
2 1
c = f V f + mVm
T. Udomphol
Ec = E f V f + EmVm
V f + Vm = 1
Transverse stiffness
1 V f Vm = + Ec E f Em
Note: let c composite f fibre m - matrix 2 1 3
2
October 2007
Chapter 2
Mechanics of composites
Example: By assuming the law of mixture, and a square array of continuous fibres, calculate the maximum and minimum moduli that can be achieved in an unidirectional reinforced composite if seven fibre mm-1 is required for the design specification, the fibres are of 100 m in diameter. Given the modulus of the fibre and the matrix are 450 and 120 GPa.
T. Udomphol
(50 10 6 ) 49
2
(10 )
3 2
= 0.385
October 2007
Chapter 2
Fabrication of composites
Nature of fibre and matrix Fibre architecture
T. Udomphol
Composite manufacturing
The development in fabrication process strongly affects commercial exploitation.
October 2007
Chapter 2
Fabrication of composites
www.imhotepcomposites.co.uk
T. Udomphol
Prepreg tapes
Chapter 2
Fabrication of composites
Sheet moulding compound
Continuous fibres are chopped and fed in the middle of resin filler pastes (from top and bottom) to produce a form of sheet. The sheet is then rolled for further compaction.
Machine for producing sheet-moulding compound
T. Udomphol
October 2007
Chapter 2
Fabrication of composites
Premixed injection moulding
T. Udomphol
Filament winding
Chapter 2
Fabrication of composites
High speed resin transfer moulding process
T. Udomphol
Chapter 2
Fabrication of composites
T. Udomphol
October 2007