TEXTILE COMPOSITES

Waqas Younus Paracha Senior Research Assistant Textile Research and Innovation Centre (TRIC) Textile Institute of Pakistan

TYPES OF ENGINEERING MATERIALS.

The basic types of engineering materials are: METALS. POLYMERS (Plastics). CERAMICS. COMPOSITES.

What is a composite?
The term "composite" can be used in several different ways, and the definition can range from general to very specific. A broad definition of a composite is: "Two or more dissimilar materials which when combined are stronger than the individual materials."

What is a composite?
While the broad definition of composites is accurate, it is too general. Composite materials (or composites for short) are engineered materials made from two or more constituent materials with significantly different mechanical properties and which remain separate and distinct within the finished structure.

CLASSIFICATION OF COMPOSITE MATERIALS:

Composite materials

Fibre reinforced composites

Carbon carbon composites

Metal matrix composites

Ceramic composites

Organic composites

Engineered wood

Plastic impregnated or laminated paper

Brief History of Composites

The use of natural composite materials has been a part of man's technology since the first ancient builder used straw to reinforce mud bricks.

HISTORY OF COMPOSITES
Israelites' use of chopped straw in their brick

HISTORY OF COMPOSITES
the Egyptian sarcophagi fashioned from glued and laminated wood veneer and also their use of cloth tape soaked in resin for mummy embalming

The Etruscan "Sarcophagus of the Spouses", at the National Etruscan Museum

HISTORY OF COMPOSITES
the Mongol warriors' high-performance, recurved archery bows of bullock tendon, horn, bamboo strips, silk and pine resin, which are 80% as strong as our modern fiberglass bows

A modern reconstruction, in fibreglass and wood, of a historical composite bow

HISTORY OF COMPOSITES
Chinese bamboo rockets reinforced with rope wrappings Japanese Samurai swords formed by the repeated folding of a steel bar back on itself the early fabrication of steel and of iron gun barrels in Damascus Roman artisans' use of ground marble in their lime plaster, frescoes and pozzolanic mortar.

Time scale of composite advancements

COMPOSITION OF A COMPOSITE MATERIAL:

Composites are made up of individual materials referred to as constituent materials There are two categories of constituent materials
matrix Reinforcement

MATRIX (RESIN SYSTEMS)

matrix holds the reinforcements in an orderly pattern the matrix also helps to transfer load Matrix materials are usually some type of plastic, and these composites are often called reinforced plastics There are other types of matrices, such as metal or ceramic, but plastics are by far the most common

MATRIX (RESIN SYSTEMS)

The choice of a resin system for use in any component depends on a number of its characteristics., with the following probably being the most important for most composite structures: 1. 2. 3. 4. 5. Adhesive Properties Mechanical Properties Micro-Cracking resistance Fatigue Resistance Degradation from Water Ingress

TYPES OF MATRIX (RESIN SYSTEMS)

Most commonly used resin systems are: Polyester resins Vinyl ester resins Epoxy resins

Some properties of resin systems:

REINFORCEMENTS
The role of the reinforcement in a composite material is fundamentally one of increasing the mechanical properties All of the different fibres used in composites have different properties and so affect the properties of the composite in different ways

REINFORCEMENTS
individual fibres or fibre bundles can only be used on their own in a few processes such as filament winding. For most other applications, the fibres need to be arranged into some form of sheet, known as a fabric, to make handling possible.

 These fabrics can be made through different textile techniques such as braiding, weaving, knitting and sometimes even Non wovens can be used as reinforcements. Therefore the utilization of all these textile techniques gave rise to the name TEXTILE COMPOSITES.

PROPERTIES OF REINFORCING FIBERS

The four main factors that govern the fibres contribution are: 1. The basic mechanical properties of the fibre itself. 2. The surface interaction of fibre and resin (the interface). 3. The amount of fibre in the composite (Fibre Volume Fraction). 4. The orientation of the fibres in the composite.

TYPICAL PROPERTIES OF SOME REINFORCEMENTS:

Material Type Tensile Strength (MPa) Tensile Modulus (GPa) Typical Density (g/cc) Specific Modulus Carbon HS Carbon IM Carbon HM Carbon UHM Aramid LM Aramid HM Aramid UHM Glass - E glass Glass - S2 glass Glass - quartz Aluminium Alloy (7020) Titanium Mild Steel (55 Grade) Stainless Steel (A5-80) HS Steel (17/4 H900) 3500 5300 3500 2000 3600 3100 3400 2400 3450 3700 400 950 450 800 1241 160 - 270 270 - 325 325 - 440 440+ 60 120 180 69 86 69 1069 110 205 196 197 1.8 1.8 1.8 2.0 1.45 1.45 1.47 2.5 2.5 2.2 2.7 4.5 7.8 7.8 7.8 90 - 150 150 - 180 180 - 240 200+ 40 80 120 27 34 31 26 24 26 25 25

WAYS TO MANUFACTURE A COMPOSITE MATERIAL

Engineered composite materials must be formed to shape The matrix material can be introduced to the reinforcement before or after the reinforcement material is placed into the mold cavity or onto the mold surface The matrix material experiences a melding event, after which the part shape is essentially set

 Depending upon the nature of the matrix material, this melding event can occur in various ways such as chemical polymerization or solidification from the melted state. In general, the reinforcing and matrix materials are combined, compacted and processed to undergo a melding event After the melding event, the part shape is essentially set

 There are different type of moulding processes which can be utilized to form a composite material. These can be Vacuum bag moulding Pressure bag moulding Autoclave moulding Resin transfer moulding (RTM)

VACUUM BAG MOULDING

AUTO CLAVE MOULDING

RESIN TRANSFER MOULDING

TEXTILE COMPOSITES...THE WAY FORWARD

APPLICATIONS IN THE AEROSPACE INDUSTRY: composite materials comprise more than 20% of the A380's airframe. Carbon-fibre reinforced plastic, glass-fibre reinforced plastic and quartz-fibre reinforced plastic are used extensively in wings, fuselage sections (such as the undercarriage and rear end of fuselage), tail surfaces, and doors.

APPLICATIONS IN THE CONSTRUCTION INDUSTRY

Textile composites have been used in construction since the 1960s, and though they do not hold a prominent place compared with that of traditional construction materials, their use is on the increase

APPLICATIONS IN THE MEDICAL INDUSTRY

Splinting materials for the repair of broken bones are not only the largest medical market for textile reinforced composites, but the oldest

APPLICATIONS IN THE SPORTS INDUSTRY

Conventional composite materials generally consist of a reinforcing textile structure and a surrounding matrix with other mechanical properties

APPLICATIONS IN THE DEFENCE INDUSTRY

In 2007 an all-composite military High Mobility Multi-purpose Wheeled Vehicle (HMMWV or Hummvee) was introduced by TPI Composites Inc and Armor Holdings Inc, the first all-composite military vehicle. By using composites the vehicle is lighter, allowing higher payloads

 Considering the given examples, one can easily see that a virtually limitless number of material combinations are possible Hence, THINK BIG THINK COMPOSITES!!!!! THANK YOU