Manufacturing with Composite

Chapter 19

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Chapter 19

Competencies

Describe the use of different types of fabrics and the importance of the fabric direction Describe the different types of matrix phases upon which composites are based. Describe the function of the primary and secondary phase in a composite material. Describe the difference between simple and ad anced composites Identify the manufacturin! techni"ues of composites #ist the ad anta!es and disad anta!es of plastics and composites

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Chapter 19

Composites
% judicious combination of two or more materials that produces a synergistic effect. % material system composed of two or more physically distinct phases whose combination produces a!!re!ate properties that are different from those of its constituents.

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Chapter 19

Composites
% composite material consists of two phases' (rimary

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*orms the matrix within which the secondary phase is imbedded %ny of three basic material types' polymers+ metals+ or ceramics -eferred to as the imbedded phase or called the reinforcin! a!ent ,er es to stren!then the composite. .fibers+ particles+ etc./ Can be one of the three basic materials or an element such as carbon or boron

,econdary

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Classification of composite material

Metal Matrix Composites (MMCs)

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Include mixtures of ceramics and metals+ such as cemented carbides and other cermets+ as well as aluminum or ma!nesium reinforced by stron!+ hi!h stiffness fibers #east common composite matrix. %luminum oxid and silicon carbide are materials that can be imbedded with fibers for impro ed properties+ especially in hi!h temperature applications Thermosettin! resins are the most widely used polymers in (1Cs. 2poxy and polyester are commonly mixed with fiber reinforcement

Ceramic Matrix Composites (CMCs)

Polymer Matrix Composites (PMCs)

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Chapter 19

Classification of composite material

1atrix material ser es se eral functions in the composite

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pro ides the bul4 form of the part or product holds the imbedded phase in place shares the load with the secondary phase

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Chapter 19

The Reinforcing Phase

The imbedded phase is most commonly one of the followin! shapes' ) *ibers ) (articles ) *la4es

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Chapter 19

The Reinforcing Phase

Fibers Diameters ran!e from .0001 in to about .000 in dependin! on the material. 6enerally circular in cross7section+ but can also be in the form of tubular+ rectan!le+ hexa!onal. *ibers used can be either continuous or discontinuous

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Continuous fibers 8 are ery lon!9 in theory+ they offer a continuous path by which a load Can be carried by the composite material Discontinuous fibers 8 are short len!ths

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Chapter 19

The Reinforcing Phase

:rientation of fibers is an important consideration. One-dimensional ) maximum stren!th and stiffness are obtained in the direction of the fiber Planar ) in the form of two7dimensional wo en fabric Random or three-dimensional ) the composite material tends to posses isotropic properties

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Chapter 19

The Reinforcing Phase

Types of fabrics Currently+ the most common fibers used in composites are !lass+ !raphite .carbon/+ boron and ;e lar &9. 6lass 8 most widely used fiber in polymer composites+ the term fiber!lass is applied to denote !lass fiber7 reinforced plastic .6*-(/

) )

27!lass 8 stron! and low cost+ but modulus is less than other .000+000 psi/ ,7!lass 8 stiffer and its tensile stren!th in one of the hi!hest of all fiber materials .300+000 psi/. <as about fi e times the tensile stren!th of steel and has a density of about one third that of steel

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The Reinforcing Phase

Carbon 8 are !enerally a combination of !raphite. 6raphite has a tensile stren!th three to fi e times stron!er than steel and has a density that is one7fourth that of steel. =oron 8 ery hi!h elastic modulus+ but its hi!h cost limits its application to aerospace components Ceramics 8 ,ilicon carbide .,iC/ and aluminum oxide .%l2:$/ are the main fiber materials amon! ceramics. =oth ha e hi!h elastic moduli and can be used to stren!then low7density+ low7 modulus metals such as aluminum and ma!nesium 1etal 8 ,teel filaments+ used as reinforcin! fiber in plastics

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The Reinforcing Phase

Particles and Flakes (articles Is an important material form for metals and ceramics ran!e in si>e from microscopic .less than 1 micron/ to macroscopic .!reater than 1 micron/

) ) )

In the microscopic si>e ran!e and proportion of imbedded material of 10? or less+ the particles result in stren!thenin! the matrix In the macroscopic si>e ran!e and proportion of imbedded material of 20? or more+ the particles ser e to share the load with the matrix material. This form of composite stren!thenin! occurs in cemented carbides+ in which tun!sten carbide .80?/ is held in a cobalt binder.

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The Reinforcing Phase

*la4es =asically+ two7dimensional particles ran!in! 0.01 to 1.0 mm in across the fla4e+ with a thic4ness of 0.001 to 0.000 mm

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METAL MATRIX COMPOSITES

Common reinforcin! phase includes ) (articles of ceramic .commonly called cermets/ ) *ibers of arious materials+ includin! other metals+ ceramics+ carbon+ and boron *-11C 8 combine the hi!h tensile stren!th and modulus of elasticity of a fiber with metals of low density+ thus achie in! !ood stren!th7to7wei!ht and modulus7to7wei!ht ratios in the resultin! composite material.

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METAL MATRIX COMPOSITES

Cemented carbides are composed of one or more Carbide compounds bonded in a metallic matrix Common cemented carbides are based on' Tun!sten carbide .@C/ Titanium carbide .TiC/ Chromium carbide .Cr$C2/ Tantalum carbide .TaC/

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METAL MATRIX COMPOSITES

Carbide ceramics constitute the principal in!redient in cemented carbides+ typically ran!in! in content from 80? to 90? of total wei!ht. (rinciple metallic binders are' ) Cobalt 8 used for @C ) Aic4el 7 used TiC and Cr$C2

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METAL MATRIX COMPOSITES

Cuttin! tools are the most common application of cemented carbides based on tun!sten carbide Titanium carbide cermets are used principally for hi!h temperature applications.

) )

Aic4el is the preferred binder9 its oxidation resistance at hi!h temperature is superior to that of cobalt. Bsed as a cuttin! tool material for machinin! steels.

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CERAMIC MATRIX COMPOSITES

Ad anta!e <i!h stiffness <ardness <ot hardness Compressi e stren!th -elati ely low density "isad anta!e #ow tou!hness and bul4 tensile stren!th ,usceptibility to thermal crac4in!

Ceramic matrix composites represent an attempt to retain the desirable properties of ceramics while compensatin! for their wea4ness.

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CERAMIC MATRIX COMPOSITES

Ceramic materials used as matrices includes'

) %lumina ) =oron carbide ) =oron nitride ) ,ilicon carbide ) ,ilicon nitride ) Titanium carbide

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POLYMER MATRIX COMPOSITES

The most important of the three classes of synthetic composites. *-( are most closely identified with the term composite. FRP % composite material consistin! of a polymer matrix imbedded with hi!h7stren!th fibers. @idely used in rubber products such as tires and con eyor belts. (rinciple fiber materials are' !lass+ carbon+ and ;e lar &9 with !lass .27!lass/ the most common fiber material
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POLYMER MATRIX COMPOSITES

%d anced composites 8 use boron+ carbon+ ;e lar as the reinforcin! fibers with epoxy as the common matrix polymer.

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POLYMER MATRIX COMPOSITES

#ybrids @hen two or more fibers materials are combined in the composite.

) )

$ntraply hybrids .within/ 7 %lternate strands of different fibers in a sin!le layer or ply .*i!. 1973/. $nterply hybrid .across/ 8 Different plies of different fibers .*i!ure 1975/.

The most widely used form if a laminar structure+ made by stac4in! and bondin! thin layers of fiber and polymer until the desired thic4ness is obtained.
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POLYMER MATRIX COMPOSITES

%ttracti e features of *-('

) ) ) ) ) ) )

hi!h stren!th7to7wei!ht ratio hi!h modulus7to7wei!ht ratio low specific !ra ity !ood fati!ue stren!th !ood corrosion resistance+ althou!h polymers are soluble in arious chemicals low thermal expansion+ leadin! to !ood dimensional stability si!nificant anisotropy in properties
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