Composite Materials-

Research and Applications

Dr. K. Padmanabhan, FIIPE, FIE, CE(I), FISME.

Professor
School of Mechanical and Building Sciences
Vellore Institute of Technology-University
Vellore 632014
 Definition
A composite material is a multi-
component system with at least a matrix
and a reinforcement.
The desired properties must be better than
at least one of the constituents.
The constituents are normally physically
separable , with a line of heterogeneity
between them, called the interface.
 Contents
Applications
Micromechanics
Meso and Macromechanics
Modelling and Simulation
Mechanical Testing
Fracture, Failure Theories and Design
Design Philosophy
Summary
Composites in Wind Energy

www.suzlon.com , www.ge.com
Vestas RRB
 Composites in Storage

Corrosion and weathering free thermoset and thermoplastic matrix

glass fibre reinforced composite storage tanks, pressure vessels and
containers are cheaper and more durable than conventional containers
Roads with Plastic Wastes
Fuel from Plastic Wastes
 Biomedical Composites

7875X10
x 1066 cycles
cyles ofof heart
heart beat
beat
over 25 years
 Composites in Dentistry
Can you make out the
difference ?

Acrylics, Acrylic esters, Bis-

GMA, PMMA derivatives,
Ceramic filled composites

Ref: K. Padmanabhan , Programme overview, NIST ceramics machining

consortium, I th Chapter, Gaithersburg, USA, October 8-9, 1998.
Composites in Automobiles

Italian automobile with carbon fibre composite chassis

 All Composite Engines

Composite Engine Manifold

Aluminium Composite Engine

 All composite Aircrafts

VTOL Aircraft

Indian Hansa-All composite aircraft

Ref: B.K. Parida, RMVGK Rao and K. Padmanabhan , Proceedings of the third joint
National Aerospace Laboratories- Chinese Aircraft Establishment workshop on
composites, April 22-24, Bangalore, India, 1996, p9. & NAL website
 Composites - Sports & Leisure

Composite Yatch

Carbon fibre-nylon matrix – rigid foam

tennis racquet
 Composites in Defense

A Bulletproof Vest A missile material case

Composites in Space

All aluminium alloy and carbon composites

 Design is defined
as the complete
information
required to
produce a
product

-
Anonymous

Micromechanics is where
design begins !
 The Fibre-Resin Micro bond

A drop of the cured resin on the Fibre pullout test through a micro
fibre surface showing adhesion vise design fixture
Micro bond Bundle Pull-out Test

Ref: K. Padmanabhan , Final project report to the Singapore –MIT Alliance ,

Singapore, November 2002
 Interface Tests
Single fibre pullout test
Single fibre push out test, brittle materials
Micro bond single fibre pullout test
Multiple fibre pullout test and Micro bond
multiple fibre pullout test, Statistically
averaged results, More precise, Less
difficult, Mesomechanical in nature.
Interlaminar shear strength test, ILSS.
 Multiple Fibre Pullout

Micro bond Matrix slab

Ref: C. Y. Yue and K. Padmanabhan , Composites B, 30(1999) p205.

Ref: K. Padmanabhan , Toyobo Confidentiality Report, 2002.

 Modelling and Analysis
Carbon Fibre and Zylon™ Fibre /epoxy
Matrix Embedded Composite Systems
Cylindrical Assemblage
• Micromechanics
Model

le Matrix

Pull Out Through a Micro vise

 Interfacial Parameters

Interfacial shear strength,τ

Interfacial frictional stress, τf
Fibre/matrix coefficient of friction, µ
Matrix shrinkage pressure, Po
Pressure due to Poisson expansion, p a
Contact pressure
Interfacial wear
 Non-linear Quasistatic
Analysis
Surface to surface
contact
CAM is anisotropic
and matrix is isotropic
Only failure and post
failure conditions were
considered due to
relevance and precision
Model has dihedral Solid 8 noded brick 185 element
symmetry Hex swept volumes
Results of ANSYS Analysis

37 MPa

Zylon/epoxy shear stress at CAM interface

FEM Analysis Results

Carbon/epoxy shear stress at CAM interface

 Micro buckling and Design
Micro buckling can be
prevented by choosing
higher fibre diameter,
higher fibre elastic
modulus and high
interfacial bond strength
between fibre and matrix
Boron fibres are the best
for design against micro
buckling
 Macromechanics
Transversely isotropic
composite needs 5
independent elastic
constants for efficient
modelling (UD/00 )
Layered orthotropic
composite needs 9
independent elastic
constants for efficient
modelling
 3 D Braided Structures

3 D braided ,knitted, stitched and

fibre preform structures have
enabled easy manufacturing of net
shape FRPs. The modelling and
performance analysis of such
structures poses challenges
 Failures and Multiple Causes
In nature, most of the real environment failures
are due to multiple causes.
As enough standard procedures are available
for failures due to a single cause, the obvious
move is to develop the understanding as well as
standard procedures for failures due to multiple
causes.
An understanding of these failures leads to a
better fracture control that aids superior designs
with advanced composite materials
 Mechanical Testing

Ref: K. Padmanabhan and Kishore , ` Failure behaviour of carbon/epoxy

composites in pin ended buckling and bending tests’, Composites, Vol:26,
No: 3, 1995, p201.
Bolted and Bonded Composite
Joints

Joint testing of a composite lug

Fracture Mechanics Testing

Mixed mode testing of composite

materials is a recent trend as
causes are multiple during failure in
real conditions

Fracture mechanics tests to

evaluate fracture toughness
and strain energy release
rates have found quite a few
standards in ASTM
Composites in Microelectronic
Packaging

The BOM includes Copper lead frame,

Gold wires for bonding, Silver –epoxy
for die attach, Silicon die and Epoxy
mould composite with Phenolics, Fused
silica powder and Carbon black powder
as the encapsulant materials.
Thermal – Structural Results

Displacement Vector sum Von mises stress

Stress intensity XY Shear stress

 Non Destructive Evaluation
Ultrasonic C-Scan NDT
can do depth profiling of
composites delamination
and damage profiling

Scanning acoustic microscope

can sense delaminations of
micron dimensions ( shown as
red areas) in TQLMP IC
packages. FEA techniques are
also NDE techniques.
 Composites in Prosthodontics
Tooth is a functionally graded
composite material with enamel
and dentin. In the third maxillary
molar the occlusal stress can
be 2-3 MPa.

The masticatory heavy chewing

stress will be around 193 MPa.
A composite restorative must with
stand this with an FOS and with
constant hygrothermal attack.
 Hygrothermal Behaviour
Fibre reinforced plastics are known for
environmental attacks that reduce their function.
Mechanical properties degrade over time !
Moisture plays havoc at elevated temperatures,
in the presence of voids, defects and in low Tg
plastics .
Diffusion and osmotic pressure are the driving
mechanisms for hygrothermal attack
Evaluation methods and surface preservation
Important in marine, biomedical, aeronautical,
electronic and automobile applications
Azzi-Tsai-Hill Failure Theory

Where,
σ11 = X ( tensile / compressive) stress in MPa
σ22 = Y ( tensile / compressive) stress in MPa
τ12 = Shear stress in MPa
SLt = Longitudinal tensile strength in MPa
STt = Transverse tensile strength in MPa
SLts = In-plane shear strength in MPa
 Tsai – Wu Failure Theory

F1 σ11 + F2 σ22 + F6 τ12+ F11 σ112+ F22 σ222+ F66 τ122+2 F12 σ11σ22 = 1

Where,
Other parameters / symbols appear on the previous slide,
SLc = Longitudinal compressive strength in MPa
STc = Transverse compressive strength in MPa.
 ASTM STP D 5229 M Rule
The MOT( Maximum Operating Temperature)
of the material, device/component should be
at least 25 º Celsius lower than the lowest Tg
(normally wet) of the material attained after
hygrothermal equillibration. All the polymeric
materials and their composites must satisfy
this rule in order to qualify for certification for
reliability and durability.
Sandwich Core Materials

Foam

Honey
comb
Sandwich Showing Core and
Skin –Core Interfacial Failure

Core failure Tensile face

Ref: ASTM C 393/C393M-06, ASTM D7249/ D 7249 M-06, ASTM D7250/

D7250M-06
 Advances in Sandwich
Composites
•Develop fracture mechanics test
methods for sandwich
composites
•Focus on facesheet core delamination
•Both Mode I and Mode II
Suitable for ASTM standardization

Ref: Dan Adams, Department of Mechanical Engg ,

Department of Mechanical Engineering
University of Utah, Salt Lake City, UT, USA
 Design Optimization

Ref: 1. G.R. Froud ,Composites, July, 1980, p 133

2. RMVGK Rao et al in Jl. Of Reinforced Plastics and Composites,
Vol:25, No: 6, 2006, p 663
Design Optimization for Strength
Glass-Epoxy Skin Showing
Buckling Delamination Type
Of Failure on the Compressive
Face.

Carbon-Epoxy Skin Showing

Buckling Delamination Type
Of Failure on the Compressive
Face.
Skin Weight= Core Weight
 Zylon Fibre
www.toyobo.co.jp
ZYLON consists of rigid-rod chain molecules of poly(p-
phenylene-2,6-benzobisoxazole)(PBO).

Tensile Strength : 5.8 GPa

Tensile Modulus : 270 GPa

Ref: K. Padmanabhan , Toyobo Confidentiality Report, 2002.

 Nanocomposites

Carbon nanotubes

The SWNT has a Tensile Modulus of 1-5 TPa and a Tensile Strength of 13-53
GPa at an elongation of 16 %. A 0. 50 Vf composite , in theory will have a tensile
strength and a modulus around half as much, assuming that the matrix is weak !
 Design Philosophy- Design
Properties
Strength, Stiffness, Toughness, Fatigue,
Creep, Impact and Damage tolerance
Dimensions, Weight, Tolerances
Judicious use of drafts, radii, fillets, webs,
ribs, blends, chamfers and curves for
specific properties
Ease of assembly, disassembly and
service
Aesthetics, colouring and texturing
 Design Philosophy-
Manufacturing Properties
Forming temperature, Glass transition, Melting
point, Rate of solidification
Energy required to form, Whether batch process
possible? , Pressure required
Flow behaviour, Viscosity, Melt flow index
Mouldability and Castability, Workability
Fabrication of Complex Parts, Time
Curing/Solidification Shrinkage in the Mould
Materials properties, Availability, Toxicity, Safety
 Design Philosophy-
Customer Requirements
Quality, Cost, Durability ( low moisture
absorption), Reliability ( low degradation of
properties with time)
Efficiency : Better properties at lighter
weight and less money, Value
Flexibility : Multi functionality
Low maintenance cost
Aesthetics, textures in Design
 Design Philosophy
Pyramidal Substantiation

The aircraft ,we hope,

is never tested

The sub-assemblies and the

assemblies
are tested the least

The subcomponents and components

are tested less often

The test specimens are tested more often

 Bibliography
P,K. Mallick, Fibre reinforced composites, Marcel and
Dekker Inc., New York .
Derek Hull and T.W. Clyne, ` An Introduction to
composite materials’, Cambridge solid state science
series, 1996.
E.J. Barbero, `Introduction to composite materials
design’, Taylor and Francis ,MI.
J.K. Kim and Y.W. Mai, `Engineered interfaces in fibre
reinforced composites ‘, Elsevier, 1998.
www.wikipedia.org
Rao Tummala, Microsystems Packaging,McgrawHill.
 Bibliography
Sanjay K Mazumdar, Composites Manufacturing, CRC
Press, 2002.
Geoffrey Pritchard, Reinforced Plastics Durability,
Woodhead publishing,Cambridge, England, 1999.
Skinner’s Science of Dental Materials , R.W. Phillips, A
Prism India ed, 1994.
ASTM Standards Handbooks Vols: 08.01,08.02 and
08.03, PA, USA.
www.astm.org
ANSYS v.11 Analysis Manuals, 2008.
Rayner M Mayer, Design with Reinforced Plastics,
Design Council, London.
 Bibliography
K. Padmanabhan, S.Subeesh, K. Balaguru and T.
Karthik , ` 3D Modelling and Failure Analyses of IC
packages’, in ANSYS Users’ Conference CD, 6 & 7
November 2008, Bangalore.
K. Padmanabhan, S.Subeesh, K. Balaguru and T.
Karthik , ` An Analyses of Reliability and
Hygrothermal Effects in IC packages’, in ANSYS
Users’ Conference CD, 6 & 7 November 2008,
Bangalore. BEST PAPER AWARD
K. Padmanabhan, D. Sanjay and S Subeesh,` Design
and electro-hygrothermo-mechanical reliability
analyses of a leadless quad IC package’, in the
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