Adv Composites

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Advanced Materials for Design and Technology Advanced Materials for Design and Technology
Advanced Composite Materials
Lecturer: Dr. Alan Kin Lecturer: Dr. Alan Kin- -tak tak Lau Lau
Tel: 2766 7730 Tel: 2766 7730
Fax: 2365 4703 Fax: 2365 4703
E E- -mail: mail: mmktlau@polyu.edu.hk mmktlau@polyu.edu.hk
Department of Mechanical Engineering Department of Mechanical Engineering
The Hong Kong Polytechnic University The Hong Kong Polytechnic University
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Content: Content:
Introduction;
Linear Elastic Stress-strain
Characteristics;
Stress-strain Relations for Plane
Stress;
Plane-stress Stress-strain Relations in
a Global Coordinate System;
Failure theories;
Materials Degradation;
Manufacturing Process and
Applications.
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Assessment criteria
Assessment criteria
Course works
Group discussions 10 %
In-class assignments 10 %
Home works 10 %
Group design projects 30 %
Written examination 40%
Total 100 %
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Introduction
Introduction
Definition of Composite Materials
In its most basic form a composite material is one, which is
composed of at least two elements working together to produce
material properties that are different to the properties of those
elements on their own. In practice, most composites consist of a bulk
material (the matrix), and a reinforcement of some kind, added
primarily to increase the strength and stiffness of the matrix. This
reinforcement is usually in fibre form. Today, the most common
man-made composites can be divided into three main groups:
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Polymer Matrix Composites (PMCs) These are the most
common and will be discussed here. Also known as FRP -
Fibre Reinforced Polymers (or Plastics) these materials use
a polymer-based resin as the matrix, and a variety of fibres
such as glass, carbon and aramid as the reinforcement.
Metal Matrix Composites (MMCs) - Increasingly found in
the automotive industry, these materials use a metal such as
aluminium as the matrix, and reinforce it with fibres such as
silicon carbide.
Ceramic Matrix Composites (CMCs) - Used in very high
temperature environments, these materials use a ceramic as
the matrix and reinforce it with short fibres, or whiskers such
as those made from silicon carbide and boron nitride.
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Most commonly, composite materials have a bulk phase, which is
continuous, called the matrix, and one dispersed, non-continuous,
phase called the reinforcement, which is usually harder and stronger.
The concept of composite materials is ancient: to combine different
materials to produce a new material with performance unattainable
by the individual constituents. The essence of the concept of
composites is this: the bulk phase accepts the load over a large
surface area, and transfers it to the reinforcement, which being
stiffer, increases the strength of the composite. The significance
here lies in that there are numerous matrix materials and as many
fiber types, which can be combined in countless ways to produce
just the desired properties.
Polymer Matrix Composites Polymer Matrix Composites
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Illustrating the combined effect on Modulus of the addition of fibres to
a resin matrix.
FRP Fibre-reinforced
polymer/plastic
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Overall, the properties of the composite are
determined by:
The properties of the fibre
The properties of the resin
The ratio of fibre to resin in the composite (Fibre Volume
Fraction (FVF), V
f
)
The geometry and orientation of the fibres in the composite
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Components of Composite Materials
Bulk phase: matrix materials Bulk phase: matrix materials
Polymers
Metals
Ceramics
Reinforcement: fibers and Reinforcement: fibers and
particulate particulate
Glass
Carbon
Organic
Boron
Ceramic
Metallic
Interface Interface
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The reinforcement system in a composite material strongly
determines the strengthening mechanism in a composite. It is thus
convenient to classify composites according to the characteristics of
the reinforcement, such as length, orientation etc.
Classification of Composite Materials
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A fibre reinforced plastic (FRP) has been recognised as one of
the most innovative materials in the applications ranging from
the aerospace industry to prevalent sport goods and facilities for
more than 30 years. It has been demonstrated that the FRP
could be successfully used to replace conventional materials for
most primary structural elements in modern aircraft with safe
and durability.
Fiber types: Carbon, E-glass and
Kevlar (Aramid)
Resin types: Polyester, Vinyl ester,
Phenolic and Epoxy
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Fabric types:
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Weft-knitted glass
fabrics
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Fibres
Fibres
Reinforcements are not necessarily in the form of long fibers. They
can be particles, whiskers, discontinuous fibers, sheets etc. A great
majority of materials is stronger and stiffer in the fibrous form than
in any other form. This explains the emphasis on using fibers in
composite materials design.
Fibers used in advanced composites have very high strength and
stiffness but low density. They also should be very flexible (to
allow a variety of methods for processing) and have high aspect
ratio (length/diameter), that allows a large fraction of the applied to
be transferred via the matrix to the fiber.
Fibers are added to a ductile matrix (like polymers and metals)
usually to make it stiffer, while fibers are added to a brittle matrix
(like ceramics) to increase toughness.
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Matrix
Matrix
Polymers used as matrix materials are commonly referred to as
resins. The matrix resin generally account for 30 to 40%, by
volume, of a composite material. In addition to maintaining the
shape of the composite structure, aligning the reinforcements
(fibres), and acting as a stress transfer medium, the matrix protects
the fibre from abrasion and corrosion. More importantly, the
limitation of a composite may well be a function of matrix
properties, such as thermal stability, chemical inertness, load
transferability, moisture absorbability, mouldability and curing
temperature.
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Thermosets
Thermosets
Thermosetting resins are the most common type of matrix system
for composite materials. They have become popular for a number
of reasons, including low melt viscosity, good fibre impregnation,
and fairly low processing temperatures. They are also lower in cost
compared to thermoplastic resins.
Polyester
Vinyl ester
Epoxy
Polyimide
50 110
100 150
50 250
280 320
40 90
127
100 200
70 120
1.2 4.5
3 4
2 6
3.1 4.9
Resin type Tg Tensile strength (MPa) E (GPa)
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Resin Systems
Resin Systems
Any resin system for use in a composite material will require
the following properties:
1. Good mechanical properties
2. Good adhesive properties
3. Good toughness properties
4. Good resistance to environmental degradation
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The figure below shows the stress / strain curve for an 'ideal'
resin system. The curve for this resin shows high ultimate
strength, high stiffness (indicated by the initial gradient) and a
high strain to failure. This means that the resin is initially stiff
but at the same time will not suffer from brittle failure.
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It should also be noted that when a composite is loaded in
tension, for the full mechanical properties of the fibre
component to be achieved, the resin must be able to deform to
at least the same extent as the fibre. The figure below gives
the strain to failure for E-glass, S-glass, aramid and high-
strength grade carbon fibres on their own (i.e. not in a
composite form). Here it can be seen that, for example, the S-
glass fibre, with an elongation to break of 5.3%, will require a
resin with an elongation to break of at least this value to
achieve maximum tensile properties.
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Interface
Interface
1. More often than not, the interface between fiber and matrix is rather
rough, instead of ideal planar.
2. To obtain desirable properties in a composite, the applied load should
be effectively transferred from the matrix to the fibers via the
interface. This means that the interface must be large and exhibit
strong adhesion between fibers and matrix. Failure at the interface
(called debonding) may or may not be desirable. This will be
explained later in fracture propagation modes.
3. Interfacial strength is measured by simple tests that induce adhesive
failure between the fibers and the matrix. The most common is the
Three-point bend test or ILSS (interlaminar shear stress test)
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Typical Internlaminar (Short Beam) Shear Test Set-up
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A good bonding interface Debond at the interface
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Mechanical Properties
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Adv Composites

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