Ken Youssefi Mechanical Engineering Dept.

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Ken Youssefi Mechanical Engineering Dept.
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What is a composite Material?
A broad definition of composite is: Two or more chemicall distinct
materials which when combined ha!e impro!ed properties o!er
the indi!idual materials. "omposites could be natural or snthetic.
#ood is a good e$ample of a natural composite% combination of cellulose fiber
and lignin. The cellulose fiber pro!ides strength and the lignin is the &glue& that
bonds and stabili'es the fiber.
The ancient Egptians manufactured composites( Adobe bric)s are a good
e$ample. The combination of mud and straw forms a composite that is
stronger than either the mud or the straw b itself.
*amboo is a !er efficient wood composite structure. The components
are cellulose and lignin% as in all other wood% howe!er bamboo is
hollow. This results in a !er light et stiff structure. "omposite fishing
poles and golf club shafts cop this natural design.
Ken Youssefi Mechanical Engineering Dept.
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Composites
Composites are combinations of two materials in which one of the material is
called the reinforcing phase% is in the form of fibers% sheets% or particles% and
is embedded in the other material called the matrix phase.
Tpicall% reinforcing materials are strong with low densities while the
matri$ is usuall a ductile or tough material. ,f the composite is designed
and fabricated correctl% it combines the strength of the reinforcement with
the toughness of the matri$ to achie!e a combination of desirable
properties not a!ailable in an single con!entional material.
-einforcement: fibers
.lass
"arbon
/rganic
*oron
"eramic
Metallic
Matri$ materials
0olmers
Metals
"eramics
,nterface
*onding
surface
Components of composite materials
Ken Youssefi Mechanical Engineering Dept.
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Composites
The essence of the concept of composites is that the load is applied
o!er a large surface area of the matri$. Matri$ then transfers the load
to the reinforcement% which being stiffer% increases the strength of the
composite. ,t is important to note that there are man matri$ materials
and e!en more fiber tpes% which can be combined in countless was
to produce 2ust the desired properties.
,n the 3nited 4tates% composites manufacturing is a 25 billion dollar
a ear industr. There are about 6777 composites related
manufacturing plants and materials distributors across the 3.4. The
industr emplos more than 2+5%777 people. An additional 257%777
people are emploed in businesses that support the composites
industr% including materials suppliers% e8uipment !endors% and other
support personnel.
About 97: of all composites produced are comprised of glass fiber and
either polester or !inlester resin. "omposites are broadl )nown as
reinforced plastics.
Ken Youssefi Mechanical Engineering Dept.
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Composites
Fibers
Matrix materials
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Composites Polymer Matrix
0olmer matri$ composites ;0M"< and fiber reinforced plastics ;=-0<
are referred to as Reinforced Plastics. "ommon fibers used are
glass ;.=-0<% graphite ;"=-0<% boron% and aramids ;Ke!lar<. These
fibers ha!e high specific strength ;strength>to>weight ratio< and specific
stiffness ;stiffness>to>weight ratio<
Matri$ materials are usuall thermoplastics or thermosets? polester%
epo$ ;@7: of reinforced plastics<% fluorocarbon% silicon% phenolic.
Ken Youssefi Mechanical Engineering Dept.
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Composites Polymer Matrix
Reinforcing fibers
.lass B most common and the least e$pensi!e% high strength% low stiffness
and high densit. .=-0 consists +7>67: glass fibers b !olume.
B highest specific strength% toughest fiber% undergoes
plastic deformation before fracture% but absorbs moisture% and is e$pensi!e.
Aramids ;Ke!lar<
B boron fibers consist of boron deposited on tungsten fibers% high
strength and stiffness in tension and compression% resistance to high
temperature% but the are hea! and e$pensi!e.
*oron
B more e$pensi!e
than glass fibers% but lower densit and higher stiffness with high strength.
The composite is called carbon>fiber reinforced plastic ;"=-0<.
.raphite ;99: carbon< or "arbon ;@7>95: carbon<
The average diameter of fibers used is usually less than .0004 inch (.01 mm.
The tensile strength of a glass fiber could be as high as !"0 #si (bul# glass
$
u
% "&1"0 #si
Ken Youssefi Mechanical Engineering Dept.
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Properties of Reinforced Plastics
The mechanical properties of reinforced plastics !ar with the )ind%
shape% relati!e !olume% and orientation of the reinforcing material% and
the length of the fibers.
Effect of tpe% length% : !olume% and orientation of fibers in a fiber
reinforced plastic ;nlon<
Ken Youssefi Mechanical Engineering Dept.
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Applications of Reinforced Plastics
0henolic as a matri$ with asbestos fibers was the first reinforced plastic
de!eloped. ,t was used to build an acid>resistant tan). ,n 1927s it was
=ormica% commonl used as counter top.% in 1917s boats were made of
fiberglass. More ad!anced de!elopments started in 19A7s.
Tpicall% although not alwas% consumer composites in!ol!e products that
re8uire a cosmetic finish% such as boats% recreational !ehicles% bathwear%
and sporting goods. ,n man cases% the cosmetic finish is an in>mold
coating )nown as gel coat.
Consumer Composites
A wide !ariet of composites products are used in industrial applications% where
corrosion resistance and performance in ad!erse en!ironments is critical.
.enerall% premium resins such as isophthalic and !inl ester formulations are
re8uired to meet corrosion resistance specifications% and fiberglass is almost
alwas used as the reinforcing fiber. ,ndustrial composite products include
underground storage tan)s% scrubbers% piping% fume hoods% water treatment
components% pressure !essels% and a host of other products.
'ndustrial Composites
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Applications of Reinforced Plastics
This sector of the composites industr is characteri'ed b the use of
e$pensi!e% high>performance resin sstems and high strength% high stiffness
fiber reinforcement. The aerospace industr% including militar and
commercial aircraft of all tpes% is the ma2or customer for ad!anced
composites.
These materials ha!e also been adopted for use in sporting goods% where
high>performance e8uipment such as golf clubs% tennis rac)ets% fishing poles%
and archer e8uipment% benefits from the light weight B high strength offered
b ad!anced materials. There are a number of e$otic resins and fibers used
in ad!anced composites% howe!er% epo$ resin and reinforcement fiber of
aramid% carbon% or graphite dominates this segment of the mar)et.
(dvanced Composites
Ken Youssefi Mechanical Engineering Dept.
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Composites Metal Matrix
The metal matri$ composites offer higher modulus of elasticit%
ductilit% and resistance to ele!ated temperature than polmer matri$
composites. *ut% the are hea!ier and more difficult to process.
Ken Youssefi Mechanical Engineering Dept.
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Composites Ceramic Matrix
"eramic matri$ composites ;"M"< are used in applications where
resistance to high temperature and corrosi!e en!ironment is desired.
"M"s are strong and stiff but the lac) toughness ;ductilit<
Matri$ materials are usuall silicon carbide% silicon nitride and aluminum
o$ide% and mullite ;compound of aluminum% silicon and o$gen<. The
retain their strength up to +777
o
=.
=iber materials used commonl are carbon and aluminum o$ide.
Applications are in 2et and automobile engines% deep>see mining%
cutting tools% dies and pressure !essels.
Ken Youssefi Mechanical Engineering Dept.
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Ken Youssefi Mechanical Engineering Dept.
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Application of Composites
0edestrian bridge in
Denmar)% 1+7 feet long
;199A<
4wedish Ca!% 4tealth
;2775<
Dance ArmstrongEs 2>lb.
Tre) bi)e% 2771 Tour de
=rance
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Advantages of Composites
"omposites ha!e a higher specific strength than man other materials. A
distinct ad!antage of composites o!er other materials is the abilit to use
man combinations of resins and reinforcements% and therefore custom
tailor the mechanical and phsical properties of a structure.
)igher $pecific $trength (strength&to&*eight ratio
The lowest properties for each material are associated with simple manufacturing
processes and material forms ;e.g. spra la>up glass fibre<% and the higher
properties are associated with higher technolog manufacture ;e.g. autocla!e
moulding of unidirectional glass fibre<% the aerospace industr.
Ken Youssefi Mechanical Engineering Dept.
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Advantages of Composites
"omposites ha!e an ad!antage o!er other materials because the can be
molded into comple$ shapes at relati!el low cost. This gi!es designers the
freedom to create an shape or configuration. *oats are a good e$ample of
the success of composites.
+esign flexibility
"omposites products pro!ide long>term resistance to se!ere chemical and
temperature en!ironments. "omposites are the material of choice for
outdoor e$posure% chemical handling applications% and se!ere en!ironment
ser!ice.
Corrosion ,esistance
Ken Youssefi Mechanical Engineering Dept.
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Advantages of Composites
/ne reason the composites industr has been successful is because of
the low relati!e in!estment in setting>up a composites manufacturing
facilit. This has resulted in man creati!e and inno!ati!e companies in
the field.
-o* ,elative 'nvestment
"omposite products and structures ha!e an e$ceedingl long life span.
"oupled with low maintenance re8uirements% the longe!it of composites is a
benefit in critical applications. ,n a half>centur of composites de!elopment%
well>designed composite structures ha!e et to wear out.
+urability
,n 191A the 3.4. "oast .uard built a series of fort>foot patrol boats%
using polester resin and glass fiber. These boats were used until the
earl 19A7s when the were ta)en out of ser!ice because the design was
outdated. E$tensi!e testing was done on the laminates after
decommissioning% and it was found that onl 2>+: of the original strength
was lost after twent>fi!e ears of hard ser!ice.
Ken Youssefi Mechanical Engineering Dept.
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Application of Composites in
Aircraft Industry
27: more fuel efficienc
and +5%777 lbs. lighter
Ken Youssefi Mechanical Engineering Dept.
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Disadvantages of Composites
The e$perience and intuition gained o!er the ears about the beha!ior of
metallic materials does not appl to composite materials.
properties in composites !ar from point to point in the material. Most
engineering structural materials are homogeneous.
Composites are heterogeneous
Composites are highly anisotropic
The strength in composites !ar as the direction along which we measure
changes ;most engineering structural materials are isotropic<. As a result%
all other properties such as% stiffness% thermal e$pansion% thermal and
electrical conducti!it and creep resistance are also anisotropic. The
relationship between stress and strain ;force and deformation< is much
more complicated than in isotropic materials.
Ken Youssefi Mechanical Engineering Dept.
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Disadvantages of Composites
"omposites materials are difficult to inspect with con!entional ultrasonic%
edd current and !isual CD, methods such as radiograph.
American Airlines =light 5@A% bro)e apart o!er
Cew Yor) on Co!. 12% 2771 ;265 people died<.
Airbus A+77Es 2A>foot>high tail fin tore off.
Much of the tail fin% including the so>called
tongues that fit in groo!es on the fuselage and
connect the tail to the 2et% were made of a
graphite composite. The plane crashed
because of damage at the base of the tail that
had gone undetected despite routine
nondestructi!e testing and !isual inspections.
Ken Youssefi Mechanical Engineering Dept.
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Disadvantages of Composites
,n Co!ember 1999% AmericaEs "up boat FYoung AmericaG bro)e in two due
to debonding faceHcore in the sandwich structure.