INTRODUCTION TO ADVANCED

COMPOSITE MATERIALS

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 Fabrication

Introduction Processing/NDT

INDUSTRIAL
COMPOSITES

Industrial Application
Design Analysis

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 Scope

Historical background, nature and advantages of composites

Types of matrices
Fibers and their characterization
Physical and mechanical properties of composites
Application in aircraft, sports goods, medical, civil engineering and automobile
industries

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 First Composite Solo Flight

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 Relative importance of Engineering Materials
with respect to time period

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 Trends of Carbon Fiber Composite Growth

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 Carbon Composites for Defence Systems

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 Composite Materials

Composite materials are

macroscopic combination of
two or more materials each
having distinct properties. It is
composed of:

1. Matrix (Black)
2. Reinforcement (White)
3. Iinterphase

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 Advantages of Composite Materials
Significant weight saving which increases
payload and/or range along with fuel
saving.
Maximum specific strength and stiffness
make them lighter than aluminum,
stronger than steel.
Permits aero-elastic tailoring of structural
components.
Flexibility of Design
Integrated structures diminishes
application of rivets.
Enhanced fatigue life.
Absence of corrosion.

Reduced operational, manufacturing

and maintenance cost.

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 Comparison of Composites with Metals

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 Aero-elastic Composite Structure

The composite structure is tailored to

meet varying aerodynamic
requirements in aircrafts, cars wind
and rotor blades. It reduces drag and
enhances energy conservation.

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Flexibility of Composite Design
 Influence of Vibrations on Composites

The vibration damping characteristics

of composites are far superior as
Compared to metals for following
reasons;
1. Matrix visco-elastic effects and
micro-cracking
2. Blunting of crack by in fibers
transverse direction
3. Debonding and sliding of fibers
in axial direction.

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 Integrated Structure
Integrated composite structure
reduces rivets and associated weight
which leads to integrated structure of
aircraft, automobiles and other
engineering systems.

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 Matrix Constituent
Roles:
Binds and holds reinforcemaent
together
Determines composite shape and
geometry
Transfers stresses to reinforcement
Types:
Ceramic (Temp < 6000°F)
Metallic (Temp < 4000°F)
Polymeric (Temp < 600°F)
Determine:
Environmental resistance
Shelf Life
Compressive & transverse
mechanical properties of composite

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 Ceramic Matrix
Oxides, carbides, nitrides, borides and silicates characterizes high degree
of thermal and dimensional stability.
Manufacturing Process:
Cast from slurries or processed into shape with organic binder and then fired/
sintered/ cured at very high temperature.
Examples:
Silicon carbide filament in Silicate matrix
Boron carbide in Alumina matrix
Aluminum oxide in Alumina matrix
Metal particles in ceramic matrix  CERMETS
Applications:
Rocket nose cone and Nozzle
Combustion Chamber
Skin of space plane/ spacecraft
Problem Areas:
Interface problem

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 Metal Matrix
Relatively lower densities of aluminum, titanium and magnesium are reinforced
by high strength/ stiffness fibers. Organic fibers are not used due to high
processing temperatures. Most common fibers are;

Metal fibers of beryllium, molybdenum, steel and tungsten

Boron, silicon carbide, silicon boride coated fine wires
Whiskers of aluminum oxide, boron carbide or silicon carbide
Manufacturing Process:
Metal matrix may be coated onto fibers by electro deposition, vapor
deposition or plasma spray followed by hot pressing
Fibers can be infiltrated with liquid metal under high process
Fiber pressed between metal foils and sintered with powder metals
Examples:
Aluminum, titanium alloys, silver, magnesium, cobalt and copper matrices
Applications:
Space shuttle, piston ring, connecting rods, suspension components

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 Polymeric Matrix
Composed of long chains of hydro carbons

Thermoplastics: Thermosets:
Softens when heated and hardens Hardens when heated.
when cooled.
Composed of long molecular cross
Can be recycled. links.
Relatively tough
Cannot be recycled.
Low dimensional stability.
Relatively brittle.
Styrenes, Vinyls, Acrylics,
Relatively greater dimensional
tolerance.
Epoxies, urathanes, phenolics.

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 Comparison of Thermoset Versus Thermoplastic

PROPERTY THERMOSET THERMOPLASTIC

(FIBERITE 931 EPOXY) (ICI APC-2 PEEK)
Melt Viscosity Low High
Fiber Impregnation Easy Difficult
Prepreg Tack Good None
Prepreg Drape Good Poor
Prepreg Stability at 0° F 6 mos. -1 yr. Indefinite
Processing Cycle 1-6 Hrs 15 sec 6 hr
Processing Temperature 350° F 700° F
Mechanical Properties Good Good
Environmental Durability Good Exceptional
Damage Tolerance Average Good
Database Large Average

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 Structural Performance Ranking of Materials

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 Temperature Response of Ceramic, Metallic &
Polymeric Composites

Polymeric composites have maximum specific strength but has poor strength
at elevated temperatures. Metal and ceramic composites retain their lower
mechanical properties at elevated temperature. Selection of composites is
21 determined by environmental temperatures.
 Properties of Polymeric Matrices
EPOXY (THERMOSET)
 Most widely used matrix in hi-tech applications
 Outstanding adhesion
 Low shrinkage during cure
 Easy to process forgiving
 Strong, tough
 Extensive, reliable data base
POLYESTER (THERMOSET)
 Most widely used matrix for less demanding applications
 High shrinkage during cure
 Poorer adhesion than epoxy
 Very easy to process ; lower pressures and temperatures and shorter cure cycles than epoxy.
 Lower cost than epoxy
 In general, poorer properties than epoxy (and less expensive)
POLYIMIDE (THERMOSET)
 Primarily for service at high temperature i.e. 600 F
 Higher cost than epoxy
 More difficult to process than epoxy ; more complex cure cycles, requires higher temperatures are pressures
 Dark colours only
 High brittleness
 Propreg does not drape well ( tends to be a little shiff)
BISMALEIMIDE (THERMOSET)
 Proposed to fill the gap between polyimide and high temperature epoxies i.e. 450 – 500 degrees F
 Better strength than epoxy at high temperature
 It has relatively simple are cycles more like epoxy than polyimide (Thus it is relatively easy to process
 Application in X-wing vertical take off/landing sibors by Aircraft /copter.
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 PHENOLIC (THERMOSET)
Expensive and difficult to process; requires high cure pressure
Good electrical resistance
• Self extinguishing and not toxic, thus it has received interest for aircraft interiors (for example :
graphite fabric reinforced phenolic facings for honeycomb floor panels )

URETHANE (THERMOPLASTIC)
Good toughness and abrasion resistance
Easily foamed and low heat transfer (thus, a common use is insulation )
Limited in service temperature
Commonly used in Reuction Injection Molding (RIM) to produce strong, stiff, light weight
“Self-skinned” structures
Reinforced with carbon fiber Ejection seats
PEEK (THERMOPLASTIC)
Tough, high impact resistance, high fracture toughness
Excellent abrasion resistance
Excellent solvent resistance
Low moisture absorption
Very high cost
New, not much data available
Requires very high processing temperature (600 degrees F) which complicates manufacturing
Prepregs are stiff (no drape); thus, flat laminates must first be made, then laminates
must be formed to shape with high temp and pressure. Manufacturing with prepregs
is still in development stage.
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 Thermoset Composites

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 Thermoplastic Composites

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 Thermoplastic Composites

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 Evolution of Epoxy Resin
Poly functional epoxy resin contains more than two epoxide group

FIRST GENERATION EPOXIES:

Example: NARMCO 5208, CIBA GEIGY – 914
Better dimensional stabile but inherently brittle.
Composed of:
 Tetra Glycidyl Derivative (Wt Fraction : 38.2 %)
 Triglycidyl Ether (33.4%)
 Dicyandiamide (5.0%)
 Poly Ether Sul Phone (23.4)

SECOND GENERATION EPOXIES:

Example: NARMCO 5245, CIBA GEIGY-924

 Addition of CTBN to original formulation

 Better damage tolerance, reduced hot /wet
performance.
 Lead to phase separation which imparts desired
toughness.

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 Reinforcement Constituent
1. Particulate: Good compression
strength but poor tensile properties,
and particles in cement.
2. Flakes: Effective solvent
resistant but difficult fabrication.
3. Whiskers: High degree of
strength but poor crack stopping
properties.
4. Fibers: Better structural
properties, crack stopping
properties, flexibility of design
requirement by changing
orientation of fibers 0°, +45°, 90°
Stacking sequence
Types of fibers i.e. glass, carbon,
kevlar & carbon

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 Milled Carbon Fibers Carbon Fiber Pellets

Chopped Carbon Fibers Carbon Fiber Mat

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 Micrographs of Carbon, Kevlar and Glass Fibers

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 Properties of High Performance Synthetic Fibers

CARBON KEVLAR GLASS

(2-Dimension) (1 Dimension) (3 Dimension)
ADVANTAGES Max specific strength Tough High temp resistance
Max specific modulus Light weight No galvanic corrosion
High temp resistance No galvanic corrosion Low notch sensitivity
DISADVANTAGES Expensive Poor compression High density
Low impact resistance Absorbs moisture Low stiffness
Promotes oxidation Difficult machining
Difficult machining Poor coupling to resin
APPLICATIONS Rocket motors Leading edges, ropes Water tank, bathroom
Aircrafts members Ballistic protection accessories, shelters

COST INDEX High (6-7) Intermediate (3) Low (1-2)

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 Microstructure of Carbon Fibers

The covalently bonded aromatic

chains of carbon fiber in the axial
direction are held together by weak
Wander wall bonds in transverse
direction. The alignment of chains in
axial direction determines their
outstanding strength.

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 Fabrication of Carbon Fiber

Carbonization:
200-250°F
Oxidation:
1000°C 
Graphitization:
2500-3000°C 
Etching of fiber surface

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 Processing Temperature
The higher degree of temperature and
tension during graphitization process
leads to greater alignment of carbon
chains and superior mechanical
properties of carbon fibers, T-300
(Boeing-727, 737, 747 and Airbus-
310) and T-800 (Boeing-777, Airbus-
380, Osprey V22 and JSF).

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 Variation of Mechanical Properties of Carbon Fiber
With Respect to Temperature

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 Chemical Kinetics of during Curing of CFRP

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 Kevlar Fibers
Kevlar: Aromatic carbon chains are held together by amide group (-CH-NH-).
Concentrated solution in strong mineral acid is processed through spinnerets into
neutralizing bath. The fibers are washed, dried and heated in nitrogen at high
temperature under tension.

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 Properties of Kevlar Fibers

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 Glass Fibers

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 Weave Architecture

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 Through Thickness Stitching

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 Fiber Architecture

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 Prepreg
Prepreg: The resin is impregnated in
fibers by passing fibers through resin
bath, oven and driers. The resin is
advanced from A to B stage. The
ready to mold material is stored for
application.

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 Unidirectional and Fabric Prepreg

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 Composite Materials Summary

Composite Materials

Matrix Interphase Reinforcment

Ceramic Metalic Polymers Particulate Flakes Fibers

Thermoset Thermoplastic Carbon Kevlar Glass

Phenolics Polyester Epoxy Acrylics PEEK Carbonates

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 THANK YOU

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