The Design of Composite Materials and Structures

What is a composite material?

A composite material is a material in which two or more distinct materials are

combined together but remain uniquely identifiable in the mixture. The most
common example is, perhaps, fibreglass, in which glass fibres are mixed with a
polymeric resin. If one were to cut the fibreglass and, after suitable preparation of
the surface, look at the material, the glass fibres and polymer resin would be
easy to distinguish. This is not the same as making an alloy by mixing two
distinct materials together where the individual components become
indistinguishable. An example of an alloy that most people are familiar with is
brass, which is made from a mixture of copper and zinc. After making the brass
by melting the copper and zinc together and solidifying the resultant mixture, it is
impossible to distinguish either between or where the atoms of copper and zinc
are. There are many composite materials and while we may be aware of some,
such a fibreglass and carbon epoxy, there are many others ranging from the
mundane, reinforced concrete ( a mixture of steel rod and concrete (itself a
composite of rock particles and cement), pneumatic tyres ( steel wires in
vulcanised rubber), many cheap plastic moldings (polyurethane resin filled with
ceramic particles such as chalk and talc) to the exotic metal matrix composites
used in the space program (metallic titanium alloys reinforced with SiC ceramic
fibres), and your automobile, such as engine pistons (aluminium alloys filled with
fibrous alumina) and brake discs (aluminum alloys loaded with wear resistant SiC
particles). Regardless of the actual composite, the two [or more] constituent
materials that make up the composite are always readily distinguished when the
material is sectioned or broken.

Is it possible to design a composite material?

Obviously the answer to that question is "Yes"! First, we must identify the
numerous materials related variables that contribute to the mechanical and
physical properties of the composite material. Secondly, the appropriate physical
and mathematical models that describe how the properties of the individual
components of the composite are combined to produce the properties of the
composite material itself must be derived. So, "Yes", it is possible to design a
composite material such that it has the attributes desired for a specific
application. Those attributes might be as simple has having a specified stiffness
and strength, a desired thermal conductivity, or have a minimum specified
stiffness at the cheapest possible cost per unit volume. Whatever the
specifications it should be possible to design a suitable composite material. As in
all design processes, it may not be possible to meet all the specifications exactly
and compromise and trade offs will be required, but by understanding the
physical origin of the required properties and developing an appropriate
mathematical description, a suitable composite can be designed. We should also
keep in mind that there may be an exisitng conventional material that is more
suitable for the application than a composite. So the composite must offer a
specific advantage in terms of cost or performance than conventional
alternatives. It is one of the goals of this resource to show you the logical steps
needed to implement the design process.