CHAPTER 16:

COMPOSITE MATERIALS

ISSUES TO ADDRESS...
• What are the classes and types of composites?
• Why are composites used instead of metals,
ceramics, or polymers?
• How do we estimate composite stiffness & strength?
• What are some typical applications?

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Composites: Best of Both Worlds

Pros Cons
• electrically, thermally conductive • dense
• good strength & ductility • low creep resistance
• high toughness Metals • low/moderate corrosion resistance
• magnetic

Pros Pros
• electrically, thermally insulating • very ductile
• wear and corrosion resistant Composites • easy to form
• high strength & stiffness • corrosion resistant
• creep resistant • high strength-to-weight ratio
• low density

Ceramics Polymers
Cons Cons
• difficult to form/machine • low stiffness & strength
• very low toughness • poor high temperature properties

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1
 Bone: A Natural Composite

http://bioweb.uwlax.edu/aplab/Table_of_Contents/Lab_05/Bone_Model_1/bone_model_1.html, doenloaded feb 26, 2005.

Composition of Mature Bone

• ~45 wt% mineral salts (calcium phosphate and calcium carbonate)
• ~35 wt% organics (collagen protein)
• ~20 wt% water

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Classifications
Matrix Phase:
Ceramic Matrix Composites Metal Matrix Composites Polymer Matrix Composite
• Improve fracture toughness • Improve strength-to-weight • Increase stiffness
• Improve creep resistance • Improve creep resistance
woven
fibers

0.5 mm
SiC fibers in vitroceramic, showing fiber pullout. Zr-Ti-Nb dendritic phase in bulk metallic glass matrix. Reprinted with permission from
www.onera.fr/dmsc-en/matcer downloaded Feb. 26, 2005 From F. Szeucs, C.P.Kim, and W. L. Johnson, Acta Mater. 49, D. Hull and T.W. Clyne, An Introduction to Composite Materials, 2nd ed.,
1507 (2001) Cambridge University Press, New York, 1996, Fig. 3.6, p. 47.

Dispersed Phase:
Fiber Particle Structural/Layered

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2
 Fiber Reinforcement
How does it work?

σ∗f = fiber
Stiff fiber tensile
• Strains less strength
• Supports matrix

Weak Matrix
τc = interface
• Strains more
shear
• Breaks first
strength

Factors to consider
• Fiber length: discontinuous vs. continous
• Loading direction: parallel vs. perpendicular
• Orientation: aligned vs. random

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Fiber Reinforcements: Length

Discontinuous vs. Continuous

σ*f d
L c > 15
2τ c

Discontinous (short) fibers: fiber length < Lc

σ(x)

Continuous Fibers: fiber length > Lc

σ(x)

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3
 Fiber Reinforcements: Loading Direction
Loading parallel to fibers: Isostrain Ö springs in parallel
σc

σm σf
Ef Em

Composite stress: σc = σfVf + σmVm

Note:
valid for Composite strain: εc = εf = εm
L>Lc σ c σ f σm
Hooke’s Law: = =
E c E f Em

Composite Stiffness:
Composite Strength:
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Fiber Reinforcement: Orientation

Aligned Fibers vs. Random Distribution

C fibers:
very stiff
fracture
very strong
surface C matrix:
less stiff
view onto plane less strong
fibers lie
in plane

SiC fibers in glass matrix.

Aligned Random
From F.L. Matthews and R.L. Rawlings, Composite
Materials; Engineering and Science, Reprint ed., CRC Carbon fibers in carbon matrix.
Press, Boca Raton, FL, 2000. Adapted from F.L. Matthews and R.L. Rawlings, Composite Materials;
Engineering and Science, Reprint ed., CRC Press, Boca Raton, FL, 2000.

Ec = KE f Vf + Em Vm

efficiency factor:
• Aligned parallel, in plane: K = 1
• Aligned perpendicular, in plane: K=0
• Random in plane: K = 3/8
• Random 3D: K = 1/5
Values from Table 16.3, Callister 6e. (Source for
Table 16.3 is H. Krenchel, Fibre Reinforcement,
Copenhagen: Akademisk Forlag, 1964.) 16 - 8

4
 Particle Reinforcement

cobalt matrix α ferrite matrix

(Vm = 10-15 vol%)
Fe3C particles
Adapted from Fig. 10.10, Callister 6e. (Fig. 10.10 is
WC particles copyright United States Steel Corporation, 1971.)

Adapted from Fig. 16.4, Callister 6e. (Fig.

16.4 is courtesy Carboloy Systems,
Department, General Electric Company.) 250 µm 20 µm
WC/Co cemented carbide spheroidite steel

rubber matrix

C particles
Adapted from Fig. 16.5, Callister 6e. (Fig. 16.5 is
courtesy Goodyear Tire and Rubber Company.)

0.25 µm
tire rubber
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Particle Reinforcement: Stiffness

Upper bound: isostrain
“Rule of Mixtures” Isostress Ö springs in series

350 Data: Cu matrix

Ef
with W particles εf
300
εm
E (GPa)

250 Em
200

150
σc = σp = σm
0 20 40 60 80 100 εc = εpVp + εmVm
σ c σp
Adapted from Fig. 16.3, Callister
6e. (Fig. 16.3 is from R.H. Krock, Vol% W particles σ
ASTM Proc, Vol. 63, 1963.)
∴ = Vp + m Vm
Lower bound: isostress E c Ep Em

Lower Bound 1 Vf Vm
= +
Composite Stiffness Ec E f Em

Application to other properties:

• Electrical conductivity, σe: replace E by σe.
• Thermal conductivity, κ: replace E by κ. 16 - 10

5
 Structural/Layered Composites

Stacked and bonded fiber-reinforced sheets

• stacking sequence: e.g., 0/90

Sandwich panels
• low density, honeycomb core

face sheet
adhesive layer
honeycomb
Ö
Adapted from Fig. 16.17, Callister 6e. (Fig. 16.17 is from
Engineered Materials Handbook, Vol. 1, Composites, ASM
International, Materials Park, OH, 1987.
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Benefits of Composites
• CMCs • PMCs
103
ceramics
fiber-reinf
102
E (GPa)

PMCs
particle-reinf 10
Force

metals
1
un-reinf 0.1
polymers
0.01
Bend displacement 0.1 0.3 1 3 10 30
10-4 Density, ρ (MG/m3)
6061 Al
• MMCs 10-6
εss (s-1)

Adapted from T.G. Nieh, "Creep rupture of a silicon-

carbide reinforced aluminum composite", Metall. Trans.
A Vol. 15(1), pp. 139-146, 1984. Used with permission.

10-8 6061 Al
w/SiC
whiskers
10-10 σ (MPa)
20 50 100 200

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6
 Summary
• Composites are classified according to:
• the matrix material (CMC, MMC, PMC)
• the reinforcement geometry (fibers, particles, layers)
• Composites enhance matrix properties:
• MMC: enhance σy, TS, creep performance
• CMC: enhance Kc
• PMC: enhance E, σy, TS, creep performance
• Fiber-reinforced:
• Elastic modulus and TS can be estimated along fiber dir.
• Properties can be isotropic or anisotropic
• Minimum fiber length needed for effective reinforcement
• Particulate-reinforced:
• Elastic modulus can be estimated
• Properties are isotropic
• Structural:
• Based on build-up of sandwiches in layered form
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