Chapter 1 Introduction

1. Definition of composite material

Combination of two or more chemically distinct material with distinct interface on a macroscopic
scale to achieve the best properties not possessed by any of the constituents acting alone.

2. Properties achieve included:
Strength, stiffness, weight, fatigue life, thermal expansion, corrosion resistance

3. Classification
1) Fibrous composite: Aircraft structures
(fiber-reinforced plastics)
Compared to Al alloy,
25% weight saving are gained.
2) Particulate Composite: composed of particles in a matrix
ex) concrete (stones at the cement matrix)



4. Material properties
1) Fiber to carry load, provide strength, stiffness
continuous
filaments
discontinuous

1. glass fiber : first one used in aircraft structures (earliest fiber)
i) E class : Si0
2
(54.4%), Al
2
0
3
(14.4%), CaO(17.5%)
ii) S class : stronger because of high percentage of Si0
2

Si0
2
(6S%), Al
2
0
3
(2S%)

2. boron fiber : Advanced Composites, 1979 present
$18u.u
lb
,
F-14, F-15 horizontal tail skin
vertical tail skin




3. Graphite fiber : low density, chemical inertness
great strength at high temperature

by mid-1970s, U.S. decided to switch from BE
p
to uiE
p

prepreg $ 40/lb (reasonable price)
1961 Japan E = 24x1u
6
psi
1964 U.S. , England E = 8ux1u
6
psi
F-16 horizontal / vertical tail skin, control surface
F-18 , wing skin, speed brake

4. Kelvar : original name PRD49(Du Pont ) :
Aramid fiber (organic fiber)
Carbon fiber reinforced plastics


2) Matrix Material to bond fibers provide stress transfer
1. metal matrix : high temperature 600F polymide usable
2. polymetric matrix - i) Thermosetting : permanent deform
ex) Epoxy
ii) Thermoplastic : After heating, it can be softened
ex) peek (kevlar matrix)
high interlaminar fracture toughness


I
K : stress intensity factor (SIF),
( ) f u : dimensionless quantity

ij I
r K o

C
I
a K o : toughness





3) Matrix material requirements
1. Elongation is greater than that of fiber.
2. Form strong joint with the fiber. (large value of
y
t
allowable)
3. Low surface tension (easy wetting in fiver) ~ .
4. Processing capability (viscosity, curing temperature)
5. Chemical stability
6. CTE (Thermal expansion coefficient ) is greater than that of fiber
m f
o o >

T = RT (room temperature, ) (250F ~300F, curing temperature)
7. Toughness

5. Residual stress calculation based on plane strain

Axisymmetric problem: no

dependency
2
2
- ,
(1 ) 1 ( )
1
(1 ) 1 ( )
1

r r
rr
rr rr
rr
du u
Strain Displacement
dr r
Constitutive eqn
E
E
Equilibrium
uu
uu
uu uu
c c
v v
c v o o o
v
v v
c v o o o
v
= =
+ AT = ( )

+ AT = ( )

0
r r
du
dr r
u
o o
+ =
B.C at
, 0, r r interface continuity condition

displacement continuity (r=a)

( ) ( )
( ) ( ) Axisymmetric
( ) ( ) Plane strain
r f r m
f f
z f z f
u u
u u
u u
u u
=
=
=





( )
yy
xx
I
xy
K
f
r
o
o u
o


=
`

)
stress continuity
0
r f r m
rrf rrm
rzf rzm rz
u u
o o
o o
o o
=
=
= =

( ) ( ) at r=a
[ (1 ) (1 )]
(1 ) (1 )(1 2 )
rr f rr m
m m f f m
m
m f f
f
E
E
E
o o
o v o v
v v v
=
+ + AT
=
+ + +


6. Reinforcing mechanism
1) Case I continuous fiber
Assumption
1. Fibers are continuous
2. Unidirectional & parallel to the loading direction
3. Perfect bonding
, ,
( )
c f m
c c f f m m
f
m
c f m
c c
c f m
c c c f f f m m m
c f f m m
P P P
A A A
A
A
A A
E E E
E E V E V rule of mixture
o o o
o o o
c c c
o c o c o c
= +
= +
= +
= =
= = =
= +

1
f f f
m m f
P E V
P E V
=

To maximize
f
m
P
P
, must increase
f
m
E
E
,
f
V

2) Case Discontinuous fiber
Chopped fiber


3) Case Particulate












Lower reinforcing mechanism

Lowest reinforcing mechanism
Typical Constitutive relation of Composites










7. Stress Distribution around broken fiber
1) Simplified model

2 2
( ) (2 ) ( )( )
f f f
a a a dz d a o t t t o o t + = +


2
(2 ) ( )
f
a
d
a a
dz
o
t t t =


2
f
a
d
dz a
o
t
=


Assume,
0
2
a
a f
const z
a
t
t t o = = = +
Symmetric argument:
0
( 0) 0
f
z o o = = =
Maximum fiber stress occurs at the center of the fiber
(
0 z =
):
max
2
2
2
a a
f a
l l l
a a d
t t
o t = = =
(
d
: diameter of fiber)



max
2
f
a
l
d
o
t
=

Let,
fu
o is ultimate fiber stress of strength.
2
fu
c
a
l
d
o
t
=

c
l -
: critical length of fiber or ineffective length.





Matrix shear stress is assumed as rigid perfectly plastic




2
f
a
d
dz a
o
t
< = >






Average fiber stress
/2 /2
0 0 /2
max max
2 2 2 1 2
2
1
1
2
c
c
l l l
a a c a
f
f f
l
c a
c
l
dz zdz dz z
l l a a a
l
l
l a
t t t
o o o
t
o o
(
= = + - =
(

( | |
= - =
| (
\ .
} } }


2)Rosens model (1964 AIAA Journal pp. 1985-91)

Assumption : 1. Perfect bonding at the interface
2. matrix only carries shear stress (fiber hard , matrix soft)
3. fibers and averaged material only carry tensile stress

Strain-displacement relation
Fiber -
' f
f f
du
u
dz
c = =
Average -
' a
a a
du
u
dz
c = =
Shear tan
a f
m f
u u
r r
| | |

= = = ~

<infinitesimal shear strain>

equilibrium equation

2 2
( ) (2 ) 0
2
0
f f f f f f
f
f
d r r r dz
d
dz r
o o t o t t t
o
t
+ + =
+ =



overall equilibrium
0
2 2 2 2
0
2 2
0 2 2
( )
1
( )
f f a a
a f f a a f
a a f f
a f
A A A
r r r r
r r
r r
o o o
o t o t o t
o o o
= +
= +
=

8 eqn & 8 unknowns
Unknowns : , , , , , , ,
f f a a a f
u u o c o c t
Equation :
...(1) , ...(2) , ...(3)
...(4) , ...(5) , ...(6)
f a f
a
f a
m f
f f f a a a
strain disp
stress strain
du u u
du
dz dz r r
E E G
c c
o c o c t

= = =

= = =

2
2
0
2 2 2 2
2
0...(7)
...(8)
f
f
f f
a
a
a f a f
fiber equilibrium
overall equilibrium
d
dz r
r
r
r r r r
o
t
o
o
o
+ =
=

Method of Solution
<key> Reduce 8 eqn. to 1 eqn. For
f
o

:
''
'
2 0 ( ) ' :
f
f
d
r dz
t
o + =
:
'
'
' '
f
a
f a f a f
m f m f m f
ua u E E
Gr G G G
r r r r r r
o
o
c c
t


= = = =


2
2
2 2 2 2
1
/ ( )
f f f
o a
m f
a a m a m f
r
r
G r r
E r r r r E
o o
o
(

= (
`

(
)

:
2 2
2 2 2 2
''
2 2
0
f o f
f
f a a m f f a a m
f
m f m f
r r
G G G
r E r r E r E r r
r r r r
o
o
o
| | | |
+
| |
| |

\ . \ .
+ =





2
1 0 f f
k o o o =

where:
( )
2
2
2 2
2 1 1
f
a a m f f m f
r
G
E r r E r r r

| |
= +
|
|

\ .
,
( )
( )
2
1
2 2
2
a
m f
f a a m
G r
K r r
r E r r
=

sol: ( ) ( )
1 2
cosh sinh
fH
c z c z o = +
1
0 2 fp
k
o o

=

( ) ( ) ( )
1
1 2 0 2
cosh sinh
fH fp
k
z c z c z o o o o

= + = + +

(2 Boundary Condition for unknowns
1
c
and
2
c
)
0
0
0
0
0
z
f
z
z L
t
o
t
=
=
=
=

'
=

for symmetry condition

<applying boundary condition>
2
0 c = ,
1 0
1 2
k
c
o

=
( )
( )
( )
( )
1 0 1 0
2 2
cosh
1 1
cosh
z z
f
z
k k
z Ce Ce
L

o o
o


| |
= =
|
|
\ .


(Using notation)
L z
z L
q
q
=
=


( )
1 0
2
1
L L L
f
k
ce e ce e
q
o
o

=



Neglect