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o The constituent materials will remain separate and distinct on a macroscopic level
within the finished structure.
o The main components of composite materials are fibers and matrix.
‐ fiber provides most of the stiffness and strength
‐ matrix binds and holds the fibers together.
o Other substances are added to improve the specific properties
S
Some generall requirements
i t off composite
it materials
t i l
The second phase (fibres or particles) uniformly distributed
throughout the matrix and must not be in direct contact with one
another
The constituents of the composite should not react with one
another at high temp; otherwise interfacial bond will become weak
leading to premature failure of the composite
In no case should the second phase loose its strength, it should be
well bonded to the matrix
Matrix must have a lower modulus of elasticity than the fibre
In g
general,, both the matrix and fibre should not have g
greatly
y
different coefficient of linear expansion
Matrix Fibre Elastic Tensile
Modulus st. (MPa)
(GPa)
long trans long trans
Al B 210 150 1500 140
Ti-6Al-4V SiC 300 150 1750 410
Al-Li Al2O3 262 152 690 180
Epoxy E-glass 40 10 780 28
Epoxy 2-D glass 16.5 16.5 280 280
cloth
Epo
Epoxy Boron 215 24 2
24.2 1400 63
Epoxy Carbon 145 9.4 1860 65
Polyester Chopped 55-138 - 103-206 -
g
glass
Al2O3 - 350-700 2-5 Flexture Fracture
St (MPa) toughness
(MPa m bar
MgO
g - 200-500 1-3
SiC - 500-800 3-6
SiO2 glass - 70-150 1
Al203 SiC 800 10
whiskers
SiO2 glass SiC fibres 1000 ~ 20
Al203 BN particulates 350 7
ROLE OF MATRIX IN COMPOSITES
Matrix binds the fibers together, holding them aligned in the
important stress direction
Loads applied to the composite and the fibers are the principal load
bearing component, through the matrix
This enables the composite to withstand compression, flexural
and shear forces as well as tensile loads.
The matrix isolates the fibers, so that they can act as separate
entities and cracks are unable to pass unimpeded/unrestricted
through sequences of fibers in contact.
The matrix protects the reinforcing filaments from mechanical
damage (e.g., abrasion) and from environmental attack.
At elevated
l t d operating
ti temperature,
t t the
th matrix
t i protects
t t
the fibers from oxidative attack.
The functions & requirements of the matrix are to:
1. Keep the fibers in place in the structure;
2. Help to distribute or transfer loads;
3 Protect the filaments
3. filaments, both in the structure and
before and during fabrication;
4. Control the electrical and chemical properties of
the composite;
5. Carry interlaminar shear.
Specific Properties for Selection of Matrix to a Specific Application
1 Minimize moisture absorption and have low shrinkage;
1.
2. Low coefficient of thermal expansion;
3 Must flow to penetrate the fiber bundles completely and eliminate
3.
voids during the compacting/curing process; have reasonable
strength,
t th modulus
d l and
d elongation
l ti ((elongation
l ti should
h ld b
be >fib
>fiber);
)
4. Must be elastic to transfer load to fibers;
5 H
5. Have strength
t th att elevated
l t d ttemperature
t (depending
(d di on application);
li ti )
6. Have low temperature capability (depending on application);
7. Have excellent chemical resistance (depending on application);
8. Be easily processable into the final composite shape;
9. Have dimensional stability (maintain its shape).
Key Factors needed for selection of Matrix
1. The matrix must have a mechanical strength commensurate
with that of the reinforcement i.e. both should be compatible.
2. Thus, if a high strength fibre is used as the reinforcement, there
is no point using a low strength matrix, which will not transmit
stresses efficiently to the reinforcement.
3. The matrix must stand up to the service conditions, viz.,
temperature, humidity, exposure to UV environment, exposure
to chemical atmosphere, abrasion by dust particles, etc.
4. The matrix must be easy to use in the selected fabrication
process and life expectancy.
5. The resultant composite should be cost effective.
Two-phase composite materials are classified into two broad categories:
(i)P ti l t composites
(i)Particulate it and
d (ii) fibre
fib reinforced
i f d composites
it
Quasi-homogeneous
Quasi-isotropic
Particulate composites
Mica
Mi flakes
fl k reinforced
i f d with
ith glass
l
(non-metallic particles in a non-metallic matrix)
Aluminium particles in polyurethane rubber
(metallic particles in a non-metallic matrix)
Lead particles in copper alloys
(metallic particles in a metallic matrix)
Silicon carbide particles in aluminium
(non-metallic particles in a metalIic matrix)
Fibre reinforced composites
Fibres
Fib off significant
i ifi t strength
t th and
d stiffness
tiff embedded
b dd d in
i a
matrix with distinct boundaries between them.
Both fibres and matrix maintain their physical and chemical
identities.
Combination performs a function which cannot be done
by each constituent acting singly.
Fibres of fibre reinforced plastic (FRP) may be short or
continuous.
continuous
FRP having continuous fibres is more efficient.
Fibre reinforced composites
Constituents of composite
o Matrix
o Dispersed phase/Reinforcement phase
Dispersed phase/Reinforcement phase
o Interface/inter‐phase
Interface
C
Composite
i
Reinforcement Matrix
Constituents of composite
o Matrix (Continuous phase) : Continuous or bulk material
o The reinforcement is generally can be in the form of fibres, particles,
whiskers or flakes
The most common man made composites can be divided into three main
groups based on the matrix
Matrix
o Carbide drills are often made from a tough cobalt matrix with hard tungsten carbide
particles inside.
o Modern high‐performance sport cars, such as those built by Porsche, use rotors
made of carbon fiber within a silicon carbide matrix.
o Ford offers a Metal Matrix Composite (MMC) driveshaft upgrade
o The F‐16 Fighting Falcon uses monofilament silicon carbide fibres in a titanium
matrix for a structural component of the jet's landing gear.
o MMCs are nearly always more expensive than the more conventional materials they
are replacing.
o As a result, they are found where improved properties and performance can justify
the added cost.
o Today these applications are found most often in aircraft components, space
systems and high‐end or "boutique" sports equipment.
Compared to monolithic metals, MMCs have the following
improved properties:
1. Higher strength-to-density ratios
2. Higher stiffness-to-density ratios
3. Better fatigue resistance
4. Better elevated temperature properties
5 Higher strength
5.
6. Lower creep rate
7. Lower coefficients of thermal expansion
8. Better wear resistance
The advantages of MMCs over polymer matrix composites are:
1 Hi
1. Higher
h ttemperature
t capability
bilit
2. Fire resistance
3. Higher transverse stiffness and strength
4. No moisture absorption
5. Higher electrical and thermal conductivities
6. Better radiation resistance
7. No out gassing
8 Fabric ability of whisker and particulate-reinforced
8. particulate reinforced MMCs
with conventional metal working equipment.
Some of the disadvantages of MMCs compared to monolithic
metals and polymer matrix composites are:
1 Higher cost of some material systems
1.
2. Relatively immature technology
3. Complex fabrication methods for fiber-reinforced systems
(except for casting)
4. Limited service experience
Stir Casting is characterized by the following features:
1. Content of dispersed phase is limited (usually <30%
30% v/v).
2. Distribution of dispersed phase throughout the matrix is not
perfectly homogeneous:
¾ There are local clouds (clusters) of the dispersed particles (fibers);
¾ There may be gravity segregation of the dispersed phase due to a
difference in the densities of the dispersed and matrix phase.
¾The technology is relatively simple and low cost
cost.
Distribution of dispersed phase may be improved if the matrix is in
semi solid condition
semi-solid condition. The method using stirring metal composite
materials in semi-solid state is called rheocasting. High viscosity of
th semi-solid
the i lid matrix
t i material
t i l enables
bl b better
tt mixing
i i off th
the di
dispersed
d
phase.
The most important MMC systems are:
1. Aluminum matrix
2 Continuous fibers: boron
2. boron, silicon carbide
carbide, alumina
alumina, graphite
3. Discontinuous fibers: alumina, alumina-silica
4. Whiskers: silicon carbide
5 P
5. Particulates:
ti l t silicon
ili carbide,
bid b boron carbide
bid
6. Magnesium matrix
7. Continuous fibers: g graphite,
p , alumina
8. Whiskers: silicon carbide
9. Particulates: silicon carbide, boron carbide
10 Titanium matrix
10.
11. Continuous fibers: silicon carbide, coated boron
12. Particulates: titanium carbide
13 C
13. Copper matrixti
14. Continuous fibers: graphite, silicon carbide
15. Wires: niobium-titanium, niobium-tin
16. Particulates: SiC, boron carbide, titanium carbide.
17. Superalloy matrices
o Ceramic Matrix composite (CMC)
o A given ceramic matrix can be reinforced with either
discontinuous reinforcements, such as particles, whiskers or
chopped fibres,
fibres particulates having compositions of Si3N4, SiC,
SiC
AlN, titanium diboride, boron carbide, and boron nitride or
with continuous fibres.
Flakes Particles
Eg. Mica Eg. Carbon black, talc
Dispersed Phase
p
Fibres Whiskers
Eg. Nylon, Sisal Eg. Graphite, SiC
Polymer matrix Composites
o Polymers constitute the most important matrix materials and are used
in more than 95% of the composite products in use today.
Polymer
Resin Elastomer
Thermosets Thermoplastic
Polymer matrix composites
¾ Thermoplastic polymer matrices‐
- Thermoplastics have low creep resistance and low thermal stability compared to thermosetting
resins.
¾ Thermoset polymer matrices‐
- Thermosetting resins are more common for the development of composite systems.
- Solidification from the liquid phase takes place by the action of an irreversible chemical cross-
linking reaction, generally in the presence of heat and pressure.
¾ Elastomer based composites‐
- The greater extensibility and high-energy
high energy storing capacity make them a suitable continuous
phase for composite materials.
- Unlike plastics, a wide variety of flexible products can be made using elastomers as the matrix
phase.
- They offer elastic strain higher than that of metals and can be stretched rapidly, even under
small loads.
Polymer matrix composites
o Polymer resins like epoxies and polyesters have
desirable properties of easily forming into complex
shapes.
o Materials like gglass and boron have extremelyy high
g
tensile and compressive strength but on application
of stress random surface flaws will cause the material
to crack even below breaking point.
o This problem can be overcome by producing the
material in the fiber form since these flaws can be
reduced.
o On mixing resin with glass, carbon and aramid,
materials of exceptional properties are obtained.
o The resin matrix spreads the load applied to the
composite between each of the individual fibers and
also protects the fibers from damage caused by
abrasive.
o High strength and stiffness, ease of moulding complex
shapes and high environmental resistance and low
densities make these composites superior to even Fig.: The combined effect on
metals for many applications. modulus of the addition
of fibers to resin matrix.
matrix
Properties of composites
o The properties of the composite are determined by
a) properties of the fiber
b) properties of the resin
c) ratio of fibre to resin in the composite and
d) geometry and orientation of the fibers in the composite.
o The higher the fiber volume fraction, the better will be the mechanical
properties of the resultant composite.
‐ However, the fibers need to be fully coated in resin to be effective.
‐ The inclusion of fiber in the manufacturing process leads to
imperfections and air inclusions.
E.g.. a) In boat‐ building industry fiber level will be 30 – 40 %.
b) In aerospace industry precise processes are used to
manufacture
f t materials
t i l having
h i 70% off fiber.
fib
Properties of composites
o There are four main direct loads that any
material in a structure has to withstand
a) Tension
b) Compression
b) Compression
c) Shear &
d) Flexure
d) Flexure.
Loading characteristics of composites
o Tension
‐ The response of a composite material to tensile loads depends on the
tensile stiffness and strength properties of the reinforcement fibers.
fibers
‐ These are far higher for fibre compared to the resin system.
o Compression
p
The adhesive and stiffness properties of the resin system are crucial, as
the resin has to maintain fibers as straight columns and prevent them
from buckling.
buckling
Shear strength
o Under shear loads the resin plays a major role in transferring the
stresses across the composite.
o For the good shear strength of composite material, the resin must
exhibit good mechanical properties and high adhesion to the
reinforcement fiber.
Fig. : The shear load applied to a composite body
Flexure
o Flexural loads are a combination of tensile, compressive and shear loads.
Fig. :The loading due to flexure on a composite body
Comparison with other structural materials
INTERCALATED EXFOLIATED
Types of nanocomposites
yp p
a) Solution blending:
- SSolvent
l t or solvent
l t mixture
i t i used
is d to
t disperse
di th nanoparticles
the ti l
and dissolve the polymer matrix.
‐ Polymer chain is then adsorbed on the nanoparticles and solvent
is removed
Disadvantages:
‐ Large amount of solvent required and product cost is high
‐ The nanoparticles may re re-agglomerate
agglomerate
o Inorganic layered silicates are able to exfoliate in water and form
colloidal particles.
o Several polymer nanocomposites,
nanocomposites including polyethylene oxide,
oxide
polyvinyl alcohol, polyacrylic acid are prepared using solution
blending.
Synthesis of nanocomposites
b) M lt bl di
b) Melt blending:
y
- Nylon 6,, p
polystyrene
y y and p
polypropylene
yp py composites
p are manufactured
f
by this method.
o This melt intercalation gives a simple way of preparing nanocomposites.
o Polar interactions of p
polymer
y and clayy surface p
playy a critical role in achievingg
particle dispersion.
o For non polar polymers (polypropylene) a compatibilizer such as maleic
anhydride modified polypropylene (PP‐MA) is commonly added to improve the
compatibility
tibilit off polypropylene
l l and
d clay.
l
o Polymers and carbon nanofibers, nanocomposites are also synthesized through this \
method.
o Shear stress is needs to be controlled at an appropriate level to disintegrate
and disperse nanoparticles.
Synthesis of nanocomposites
c) In situ polymerization:
c) In situ polymerization:
o Only viable method for most thermoset polymer to prepare
nanocomposites.
[
o Carbon nanotubes and nanofibers have also been synthesized via in situ
polymerization. 10 wt% of polystyrene was added into the mixture of
styrene and carbon nanofibers to achieve a higher initial viscosity and
consequently a more stable fiber suspension.
n-1
n-1
Methacryloxyl-oxyethyl
DHTAC Hexadecyl-dimethyl
Ammonium bromide
Synthesis of PVC nanocomposites
1) By melt blending:
o Used to prepare exfoliated nanocomposites of PVC.
o Particles
P ti l used d include
i l d clay,
l calcium
l i carbonate
b t hydrosulphite,
h d l hit copper and
d
antimony trioxide.
o The polar nature of the C‐Cl bond makes it possible to form exfoliated
nanocomposites of PVC in melt blending.
o A plasticizer like dioctylphthalate may serve as a co‐intercalate to
increase clay dispersion in PVC.
PVC
2) In situ polymerization:
o Clay
l nanocomposites off PVC haveh b
been prepared
d by
b either
h emulsion
l
polymerization or suspension polymerization.
o In ggeneral in situ p
polymerization
y methods can achieve much better clayy
dispersion.
Synthesis of PVC nanocomposites
o Highly exfoliated PVC clay nanocomposites can also be produced by flocculating
a mixture of polymer and clay mineral dispersion.
(or)
o By solution
l i blending.
bl di
‐ Organoclay tends to induce the degradation of PVC because of its low thermal
stability.
o Since the fiber reinforced polymers exhibit low elastic modulus and high
strength they are used in several orthopedic applications.
strength, applications
Composites in biomedical applications
b) The polymer composite materials are fully compatible with the modern
diagnostic methods such as computer tomography and magnetic resonance
imaging as they are non‐magnetic.
S N
S. No. Ad
Advantages
t Di d
Disadvantages
t
1 Weight reduction Cost of raw materials and fabrication
High strength or stiffness to weight
ratio
2 Tailorable properties Transverse properties may be weak
Can tailor strength or stiffness to be
in the load direction
6 I h
Inherent
t damping
d i A l i is
Analysis i difficult
diffi lt
exothermic heat
Ti>Steel>Mg>Al
g
pecific ten
Sp