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Dr.Suat CANOULLARI
All composite materials consist of two phases: 1. Primary phase - forms the matrix within which the secondary phase is imbedded 2. Secondary phase - imbedded phase sometimes referred to as a reinforcing agent, because it usually serves to strengthen the composite The reinforcing phase may be in the form of fibers, particles, or various other geometries
2002 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 2/e
Composite Materials
1. Metal Matrix Composites (MMCs) - mixtures of ceramics and metals, such as cemented carbides and other cermets 2. Ceramic Matrix Composites (CMCs) - Al2O3 and SiC imbedded with fibers to improve properties, especially in high temperature applications The least common composite matrix 3. Polymer Matrix Composites (PMCs) - thermosetting resins are widely used in PMCs Examples: epoxy and polyester with fiber reinforcement, and phenolic with powders
2002 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 2/e
2002 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 2/e
Matrix Considerations
End Use Temperature Toughness Cosmetic Issues Flame Retardant Processing Method Adhesion Requirements
Types of Fibers
Fiber Glass
Graphite Fiber
Kevlar Fiber
11 Kevlar/Carbon Hybrid
Composite Survey
Composites
Particle-reinforced Fiber-reinforced Structural
Largeparticle
Dispersionstrengthened
Continuous (aligned)
Discontinuous (short)
Laminates
Sandwich panels
Aligned
Randomly oriented
Composite Survey
Particle-reinforced -- two approaches.
E(GPa) 350 Data: Cu matrix 30 0 w/tungsten 250 particles 20 0 150 0
Fiber-reinforced
Structural
(Cu)
(W)
-- Electrical conductivity, se: Replace E in the above equations with se. -- Thermal conductivity, k: Replace E in above equations with k.
Figure 9.5 - (a) Model of a fiber-reinforced composite material showing direction in which elastic modulus is being estimated by the rule of mixtures (b) Stress-strain relationships for the composite material and its constituents. The fiber is stiff but brittle, while the matrix (commonly a polymer) is soft but ductile.
2002 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 2/e
Figure 9.6 - Variation in elastic modulus and tensile strength as a function of direction of measurement relative to longitudinal axis of carbon fiber-reinforced epoxy composite
2002 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 2/e
Fiber Alignment
Adapted from Fig. 16.8, Callister 7e.
aligned continuous
sc = smVm + sfVf
volume fraction
but
c = m = f
isostrain
Ece = Em Vm + EfVf
Ff E fVf Fm E mVm
c= mVm + fVf
transverse modulus
Remembering: E = s/ and note, this model corresponds to the lower bound for particulate composites
An Example:
UTS, SI 57.9 MPa 2.4 GPa Modulus, SI 3.8 GPa 399.9 GPa
(241.5 GPa)
(9.34 GPa)
Stacked and bonded fiber-reinforced sheets -- stacking sequence: e.g., 0/90 or 0/45/90
-- benefit: balanced, in-plane stiffness
Sandwich panels
-- low density, honeycomb core -- benefit: light weight, large bending stiffness
face sheet adhesive layer honeycomb
Adapted from Fig. 16.18, Callister 7e. (Fig. 16.18 is from Engineered Materials Handbook, Vol. 1, Composites, ASM International, Materials Park, OH, 1987.) Adapted from Fig. 16.16, Callister 7e.