Composite Materials

ISSUES TO ADDRESS...
What are the classes and types of composites?

Why are composites used instead of metals, ceramics, or polymers? How do we estimate composite stiffness & strength?
What are some typical applications?

 A composite is a structural material that consists of two or more combined constituents that are combined at a macroscopic level and are not soluble in each other Three criteria:
1. Both constituents have to be present in reasonable proportions, say greater than 5%. 2. It is only when the constituent phases have different properties, and hence the composite properties are noticeably different from the properties of the constituents. 3. A composite is usually produced by intimately mixing and combining the constituents by various means.

 Matrix: The continuous phase Purpose: ~ transfer to other phases ~ protect phases from environment Classification: MMC, CMC, PMC metal ceramic polymer Dispersed Phase: Purpose: enhance matrix properties ~ MMC: increase sy, TS, creep ~ CMC: increase Kc ~ PMC: increase E, sy, TS, creep Classification: Particle-reinf, fiber-reinf, lammellar
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(MMC, PMC, CMC)

Fibrous

Natural

Reinforcement

Particulate

Synthetics

 Particulate reinforcements have dimensions that are approximately equal in all directions. The shape of the reinforcing particles may be spherical, cubic, platelet or any regular or irregular geometry. A fibrous reinforcement is characterized by its length being much greater than its cross-sectional dimension. However, the ratio of length to the cross-sectional dimension, known as the aspect ratio, can vary considerably. Multilayered composites are another category of fibre reinforced composites. These are classified as either laminates or hybrids.
Laminates are sheet constructions which are made by stacking layers (also called plies or laminate and usually unidirectional) in a specified sequence. Hybrids are usually multilayered composites with mixed fibres.

Particle-reinforced

Fiber-reinforced

Structural

Stacked and bonded fiber-reinforced sheets -- stacking sequence: e.g., 0/90

-- benefit: balanced, in-plane stiffness

Sandwich panels

-- low density, honeycomb core -- benefit: small weight, large bending stiffness
face sheet adhesive layer honeycomb

Fiber forms

Chopped strands

Yarns

Woven fabric
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Fiber forms

X-mat bidirectional unidirectional

Roving

Mats

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(a) particulate, random; (b) discontinuous fibres, unidirectional; (c) discontinuous fibres, random; (d) continuous fibres, unidirectional.

Particle-Reinforced Composites
- Automobile matrix: rubber tires
(compliant) 0.75 mm particles: C (stiffer)

- WC/Co cemented carbide

matrix: cobalt (ductile) Vm : ~ 90 vol%!

particles: WC (brittle, hard) 600 mm

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Wood
the longitudinal hollow cells of wood are made up of layers of spirally wound cellulose fibres with varying spiral angle, bonded together with lignin during the growth of the tree
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Properties of the matrix material

Properties of the reinforcement material

Factors influence Composite properties

Matrix reinforcement bonding/adhesion Mode of fabrication

Ratio of matrix to reinforcement

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 The amount of reinforcement that can be incorporated in a given matrix is limited by a number of factors. Particulate reinforced metals the reinforcement content is usually kept to less than 40 vol. % (0.4 volume fraction) because of processing difficulties and increasing brittleness at higher contents. The processing methods for fibre reinforced polymers are capable of producing composites with a high proportion of fibres, and the upper limit of about 70 vol. % (0.7 volume fraction) is set by the need to avoid fibre-fibre contact which results in fibre damage.
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 Finally, the fact that the reinforcement is bonded to the matrix means that any loads applied to a composite are carried by both constituents In most cases the reinforcement is the stiffer and stronger constituent; it is the principal load bearer The matrix is said to have transferred the load to the reinforcement

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 The fabrication and properties of composites are strongly influenced by the proportions and properties of the matrix and the reinforcement Volume fractions: Weight fractions: vf = Vf/Vc and vm = Vm/Vc wm = Wm/Wc

wf = Wf/Wc and

Where m, f, and C refer to the matrix, fibre (or in the more general case, reinforcement) and composite respectively.
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c = fvf + mvm
is not applicable to density only, but, in certain circumstances, may apply to other properties of composites A generalized form of the equation is

Xc = Xfvf + Xmvm
Where Xc represents an appropriate property of the composite. This equation is known as the LAW OF MIXTURE
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Continuous fibers - Estimate fiber-reinforced composite

strength for long continuous fibers in a matrix Longitudinal deformation

c = mVm + fVf
volume fraction Ece = Em Vm + EfVf

but

c = m = f
isostrain

longitudinal (extensional) modulus

Ff E fVf Fm E mVm

f = fiber m = matrix

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In transverse loading the fibers carry less of the load - isostress c = m = f = c= mVm + fVf
1 Vm Vf E ct E m E f

transverse modulus

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 The chemical and strength characteristics of the interface between the fibres and the matrix is particularly important in determining the properties of the composite. The interfacial bond strength has to be sufficient for load to be transferred from the matrix to the fibres if the composite is to be stronger than the unreinforced matrix. The shape, size, orientation and distribution of the reinforcement and matrix features such as the grain size for polycrystalline matrices significantly affect the properties of the composite.
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 Ideally, a composite should be homogeneous. Maintaining a uniform distribution of the reinforcement is an important factor. The orientation of the reinforcement within the matrix affects the isotropy of the system.

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Pultrusion
Continuous fibers pulled through resin tank, then preforming die & oven to cure
Performs of desired shape, Establishes the resin/fiber ratio Precision machine to impart the final shape

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The advantages are: Process may be automated High production rates Variety of shapes,constant cross-sections, long pieces may be produced The disadvantage shapes are limited to those having a constant cross-section.

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Filament Winding

Ex: pressure tanks Continuous filaments wound onto mandrel to form a hollow (usually cylindrical) shape

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The advantages are: Process may be automated Variety of winding patterns are possible High degree of control over winding uniformity and orientation The disadvantage variety of shapes is limited

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Manufacturing of Boat

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Boat and Inflatable Boat

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Pole-vaulting
Lightweight - low density Buckling resistance - stiffness Strong - yield strength Minimal twisting Cost

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Boeing 757-200
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What are the classes and types of composites? Why are composites used instead of metals, ceramics or polymers? How do we estimate composite stiffness & strength? What are some typical applications of composite materials?

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 CMCs:

Increased toughness
particle-reinf

PMCs:

Increased E/r
ceramics

Force

E(GPa) 2 PMCs 10 10 1

103

fiber-reinf un-reinf

metal/ metal alloys

Bend displacement 10 -4
MMCs: 6061 Al ss (s-1) 10 -6

.1 G=3E/8 polymers .01 K=E .1 .3 1 3 10 30 Density, r [mg/m3]

Increased creep resistance

10 -8 10 -10

6061 Al w/SiC whiskers

20 30 50

(MPa) 100 200

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i) the modulus of elasticity ii) the tensile strength iii) the fraction of the load carried by the fiber for the following composite material stressed under isostrain conditions. The composite consists of a Kevlar 49 fiber-epoxy composite produced by using 63% by volume of Kevlar fibers having a modulus of elasticity of 27.5 X 106 psi and tensile strength 0.55 X 106 psi and a hardened epoxy resin with a modulus of elasticity 0.55 X 106 psi and a tensile strength 11.0 X 106 psi.
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