Composite Materials

Definition:
A composite material is a combination of
two or more chemically distinct and
insoluble phases with recognizable
interface, in such manner that its properties
and structural performance are superior to
those of the constituents acting
independently.
(Book definition p.238)
Quick examples:
Every day use to space ship applications…
•First engineering application 1907:
acid-resistant tank (Phenolic resin with asbestos fibers)
•Steel-wire reinforced tires;
•Snow boards / skis;
•Tennis raquets;
•Protective gear;
Quick
examples:

Reinforced
concrete;

2 x more
resistant
(compression)
 Quick examples:
Sailboard
(see p.249);
 Quick examples:
Fiberglass;
 Quick examples:

Brake pads / rotors;

 Quick examples:

High speed
fan blades;
 Quick examples:
High performance racing body parts;
Structure of reinforced plastics (composite)

Don’t get confused by the PLASTIC appellation.

Reinforced plastics: also know as polymer-matrix

composites & fiber-reinforced plastics.

Two phases:
1 . Fibers (discontinuous)
2. Matrix (continuous)
 Polymer matrix composite
• A polymer matrix composite (PMC) is a composite
material composed of a variety of short or continuous
fibers bound together by an organic polymer matrix.
PMCs are designed to transfer loads between fibers
through the matrix. Some of the advantages with PMCs
include their lightweight, high stiffness and their high
strength along the direction of their reinforcements.
Other advantages are good abrasion resistance and
good corrosion resistance
 fiber-reinforced plastics
• is a composite building material that consists of three components:
(i) the fibers as the discontinuous or dispersed phase, (ii) the matrix
as the continuous phase, and (iii) the fine interphase region, also
known as the interface. This is a type of advanced composite group,
which makes use of rice husk, rice hull, and plastic as ingredients.
This technology involves a method of refining, blending, and
compounding natural fibers from cellulosic waste streams to form a
high-strength fiber composite material in a polymer matrix. The
designated waste or base raw materials used in this instance are
those of waste thermoplastics and various categories of cellulosic
waste including rice husk and saw dust.
 Fibers:

Known as a slender, elongated, threadlike

object or structure
 Fibers: (continued)

They combine high strength and high stiffness.

Variety
Graphite – Glass – Boron – Polymer;
Others (boron carbide, steel, aluminium oxide, etc.)

When more then two fibers are used, the composite is called a hybrid.

Percentage of fibers in reinforced plastics varies from 10% to 60%.

Anything higher then 65% usually result in lower structural properties.

Fibers are sometimes treated with a coating to increase bonding strength

between fiber and matrix.
 Fibers: (continued)
Cross-section usually less then 0.0004 in. (hair =0.001in)
Sensible to defects

Short & long fibers: In a given type of fiber, if the mechanical

properties improve as a result of increasing the average fiber length,
then it is call a short fiber. Otherwise it’s a long fiber.

Continuous fibers: Offers a better control on composite’s reaction.

Generally use for oriented forces or for increased properties.
 Matrix

Known as the bonding substance.

 Matrix (continued)

Tough and generally chemically inert.

Functions:
• Support the fibers in place and transfer the stress to
them while they carry most of the load;
• Protect the fibers against physical damage and the
environment;
• Reduce the propagation of cracks in the composite
by virtue of the greater ductility and toughness of the
plastic matrix.
 Matrix (continued)

Thermosets: epoxies (80%) – polyester - silicon

Thermoplastics: Polyetheretherketone; thougher then

thermosets, but lower temperature resistance;

Metals: aluminium – magnesium - titanium

Ceramics: silicon carbide/nitride – aluminium oxide - mullite

 Properties
The mechanical and physical properties of reinforced plastics
depend on type, shape, and orientation of the reinforcing material,
the length of the fibers, and the volume fraction of the reinforcing
material.

Short fibers are less effective than long fibers.

Bond strength between fibers and matrix is a critical to avoid fiber

pullout and delamination, and to maintain good load transmission.
 Composite Manufacturing
Processes

• Open Mold Process

• Hand-Lay-Up

• Spray Up Molding

• Pultrusion
 Open Mold Processes

• Only one mold (male or female) is needed and may be made of any
material such as wood, reinforced plastic or , for longer runs, sheet
metal or electroformed nickel. The final part is usually very smooth.

• Shaping. Steps that may be taken for high quality

• 1. Mold release agent (silicone, polyvinyl alcohol, fluorocarbon, or
sometimes, plastic film) is first applied.

• 2. Unreinforced surface layer (gel coat) may be deposited for best

surface quality.
 SPRAY-UP MOLDING
• A spray gun supplying resin in two converging
streams into which roving is chopped
· Automation with robots results in highly
reproducible production
· Labor costs are lower
 The different stages of existence of
composite constituents up to the final
product
• Stage a: At this stage, the materials appear in raw basic form. For
fibers, these consist of fiber either in the form of filaments or fiber
bundles. Fibers may also be woven into fabrics or braided into
braided perform. For matrix, the material usually appears in liquid
form for thermoset resin or in granular form in the case of
thermoplastics.

• Stage b: At this stage, the fibers and matrix may be combined into a
single layer. For the case of thermoset matrix composite,the matrix
may appear in a semi-liquid, semi-solid form so that the sheet can
hold its shape. For the case of thermoplastic composite, the matrix
is solidified. This form for thermoset matrix composites is called
prepreg. For thermoplastic composites, it is called towpreg.
• Stage c: At this stage, the layers in stage b are stacked on top of
each other to make flat plate laminates. This intermediate step is
important for the analysis where material properties are tested or
calculated. However this step is usually bypassed in the
manufacturing process of practical composite parts.

• Stage d: This is the final stage where the final product configuration
is formed.
 For making a composite part, a
manufacturer can combine or alternate
these steps, depending on the requirements
for quality and cost, as follows :
• For hand-lay-up in open mold for fiber glass/polyester, dry tows or
dry fabrics are laid on a mold, liquid resin is then poured and spread
onto the fiber beds. A few layers are wetted and left to cure in open
air. After these layers are cured, more layers are added.

• For pultrusion, the dry tows are run through a bath of resin to be
wetted. These are then fed into a heated die. The fibers and resin
are subjected to compaction and heating. When the assembly of
fibers and resin exit the die, they are compacted and cured.
 Hand Lay-Up: The resin and fiber (or pieces cut from
prepreg) are placed manually, air is expelled with
squeegees and if necessary, multiple layers are built up.
· Hardening is at room temperature but may be improved by
heating.
· Void volume is typically 1%.
· Foam cores may be incorporated (and left in the part) for greater
shape complexity. Thus essentially all shapes can be produced.
· Process is slow (deposition rate around 1 kg/h) and labor-
intensive
· Quality is highly dependent on operator skill.
· Extensively used for products such as airframe components,
boats, truck bodies, tanks, swimming pools, and ducts.
Advantages
Low cost tool
Wide range of products

Disadvantages
Time consuming
Easy to form air bubbles
Disorientation of fibers
Inconsistency
Application
Making a custom parts in low to medium volume quantities
Bathtubs
Swimming pools
Boat hulls
Storage tanks
Furniture components
 Process of Pultrusion

• Continuous roll of reinforced fibers

• Tension roller
• Resin impregnator
• Resin soaked fiber
• Die and heat source
• Pull mechanism
• Finish hardened fiber
Advantages:
Automated processes
High speed
Versatile cross sectional shape
Continuous reinforcement

Disadvantages:
Die can be easily messed up
Expensive die
Mainly thermoset matrix
 Orientation of fibers
Random(5-25%)
(mostly short or long fibers, not continuous)

Orthogonal (20-40%) Unidirectional (100%)

 Various metal matrix

TABLE 9.3
Fiber Matrix Applications
Graphite Aluminum Satellite, missile, and helicopter structures
Magnesium Space and satellite structures
Lead Storage-battery plates
Copper Electrical contacts and bearings
Boron Aluminum Compressor blades and structural supports
Magnesium Antenna structures
Titanium Jet-engine fan blades
Alumina Aluminum Superconductor restraints in fission power reactors
Lead Storage-battery plates
Magnesium Helicopter transmission structures
Silicon carbide Aluminum, titanium High-temperature structures
Superalloy (cobalt-base) High-temperature engine components
Molybdenum, tungsten Superalloy High-temperature engine components