COMPOSITE MATERIALS

TECHNOLOGY

Topics: Polymer Matrix Composites-Matrix Resins-

Thermosetting resins, Thermoplastic resins.

Presented by subject staff

Gidla Vinay Dr.T.Senthilvelan
(17ME320) Professor
M.Tech (PDM) Mechanical Department
 Classification based
on Matrices
Composite
materials

Matrices

Polymer Matrix Metal Matrix Ceramic Matrix

Composites (PMC) Composites MMC) Composites (CMC)

Thermoset Thermoplastic Rubber

 What is a polymer?
Poly = many mer = repeat unit

A polymer is a large molecule (macromolecule) composed of

repeating structural units typically connected by covalent chemical
bonds

Examples of polymers:
repeat repeat repeat
unit unit unit
H H H H H H H H H H H H H H H H H H
C C C C C C C C C C C C C C C C C C
H H H H H H H Cl H Cl H Cl H CH3 H CH3 H CH3
Polyethylene (PE) Polyvinyl chloride (PVC) Polypropylene (PP)
 Polymer Matrix Composite
(PMC)
Polymer Matrix Composite (PMC) is the material consisting of a
polymer (resin) matrix combined with a fibrous reinforcing dispersed
phase.

Polymer Matrix Composites are very popular due to their low cost and
simple fabrication methods.
 Polymer(Matrix) Composite (Matrix + Reinforcement)
Discontinuous phase Reinforcement
Continuous phase - Matrix
Reinforcement
Principle Load bearing member
Matrix
provides a medium for binding and holding the reinforcements
together into a solid.
protects the reinforcement from environmental degradation.
serves to transfer load from one insert (fibre, flake or particles)
to the other.
Provides finish, colour, texture, durability and other functional
properties.
 Classification of
Polymers
Linear polymer - Any polymer in which molecules are in the form of
chains.

Thermoplastic polymers - Linear or branched polymers in which

chains of molecules are not interconnected to one another.

Thermosetting polymers - Polymers that are heavily cross-linked to

produce a strong three dimensional network structure.

Elastomers - These are polymers (thermoplastics or lightly cross-

linked thermosets) that have an elastic deformation > 200%.
 Molecular chain configurations
a)Linear polymers b)Branched polymers

c)Cross linked polymers d)Ladder polymers

 Polymerization
1)Condensation polymerization:
stepwise reaction of molecules occurs and in each step a
molecule of a simple compound, generally water, forms as a byproduct
Ex: Epoxy

2)Addition polymerization:
monomers join to form a polymer Without producing any
byproduct, generally carried out in presence of catalysts.

Ex: polyethylene
linear addition of ethylene molecules(CH2) results in polyethylene( a
chain of ethylene molecules).

final mass=sum of monomer masses

Degree of polymerization = No of monomer units in a chain

103 to 105
 Thermoplastics
Polymers that are soften or melt on heating are called thermoplastic
polymers and are suitable for liquid flow forming.
Ex: polyethylene (low and high density), polystyrene

They are held in place by weak secondary bond (intermolecular force),

such as van der Walls bonds and hydrogen.
Thermoplastics can be either amorphous or semi crystalline
In amorphous thermoplastics, molecules are randomly arranged;
whereas in the crystalline region of semi-crystalline plastics, molecules
are arranged in an orderly fashion.

a)Amorphous b)semi crystalline

Thermoplastic Resins:
Nylon
Polyester
PEEK
Polyphenylene Sulfide (PPS)
Polycarbonate
Acetyl
Polyethylene
Teflon
Nylon:
Nylon is made of repeating units linked by peptide bonds.
Nylons are also called polyamides. There are several types of nylon,
including nylon 6, nylon 66, nylon 11, etc.

Characteristics:
Good surface appearance and good lubricity.
They absorb moisture, which affects the properties and dimensional
stability of the part.
Polypropylene (PP):
An addition polymer made from the monomer propylene.
Polypropylene (PP) is a low-cost, low-density, versatile plastic and is
available in many grades and as a co-polymer (ethylene/propylene).

Characteristics:
It has the lowest density (0.9 g/cm3) of all thermoplastics and
offers good strength, stiffness, chemical resistance, and fatigue
resistance.
polypropylene has a very high resistance to electricity and is very
useful for electronic components
Polyetheretherketone (PEEK):
PEEK polymers are obtained by step growth polymerization
PEEK offers the possibility of use at high service temperatures.
They can be used continuously at 250C.
The glass transition temperature (Tg) of PEEK is 143C and
crystalline melting temperature is 336C.

Characteristics:
Good radiation resistance
Outstanding wear and abrasion resistance
Low coefficient of friction
Polyphenylene Sulfide (PPS)
Linear polymer of modest molecular weight and low mold shrinkage
It has a maximum crystallinity of 65%.
High operating temperatures and can be used continuously at 225C. The
Tg of PPS is 85C and crystalline melt temperature is 285C.

Characteristics:
Heat resistance that makes continuous usage possible at 200C or
higher
PPS polymer is inherently UL V-0 (self-extinguishing)
Chemical resistance second only to fluorinated polymers (PTFE)
Very complex, high precision molding is achievable
Very low moisture absorption
 Thermosets

If the molecules in the polymer are cross linked in the form of a

network, they do not soften on heating, such polymers are called
thermosetting polymers

Why Crosslinks?
Thermosets = resin + hardener = crosslinks

Also called as network polymers

Hardener ?
 The cross-links form during the polymerization of the liquid resin and
hardener, so the structure is almost always amorphous

Extensive cross-linking fo r me d b y covalent bonds.

B o n ds prevent chains mov in g relative to each other.
 Glass Transition Temperature (Tg)
The Glass Transition Temperature (Tg) is the temperature range where
a thermosetting polymer changes from a hard, rigid or glassy state to
a more pliable, compliant or rubbery state.
Thermoset types
Epoxy

Polyster resins

Phenolic

Vinylesters

Cyanate Esters

Bismaleimide (BMI) and Polyimide

Epoxy:
Epoxy is a polymer that contain an epoxide group in its chemical
structure. Epoxy resins may be reacted (cross linked) either with
themselves through catalytic homopolymerisation, or with a wide range
of co-reactants.
Example: DGEBA (Diglcidyl Ether of Bisphenol A )

Characteristics:
Reasonably stable to chemical attacks
Serve up to temperature of 140C
Slow shrinkage during curing
Polyesters:
A condensation reaction between a glycol and an unsaturated dibasic
acid results in polyester. This contains a double bond C=C between its
carbon atoms.
Example: poly ethylene terephthalate (PET).

Characteristics:
Cheap
Offer excellent corrosion resistance
Resistance to variety of chemicals
Adequate moisture resistance
Used up to 75C
Phenolic:
Phenolic are formed by the reaction of phenol (carbolic acid) and
formaldehyde, and catalyzed by an acid or base.
Phenolic are generally dark in color.

Characteristics:
Offer High temperature resistance.
Good Electrical properties
Good Wear resistance
chemical resistance and dimensional stability.
Some of the basic properties of selected thermoset resins
 Role of matrix
In a composite material, the matrix material serves the following
functions:

Holds the fibers together.

Protects the fibers from environment.
Distributes the loads evenly between fibers so that all fibers are
subjected to the same amount of strain.
Enhances transverse properties of a laminate.
Improves impact and fracture resistance of a component.
Avoid propagation of crack growth and by providing alternative path
for the failure.
Carry inter laminar shear.
 Desired properties of a matrix
Reduced moisture absorption.
Low shrinkage.
Low coefficient of thermal expansion.
Good flow characteristics so that it penetrates the fiber bundles
completely and eliminates voids during the compacting/curing
process.
Must be elastic to transfer load to fibers
Dimensional stability (maintains its shape).
Excellent chemical resistance (depending on application)
Thank you

Reference:
Composite materials science and engineering by Krishna K.Chawla
Composites manufacturing by Sanjay K Mazumdar
www.Epotek.com
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Wikipedia