Composite Material
Composite Material
Composite Material
1 History
The earliest man-made composite materials were
straw and mud combined to form bricks for building
construction. Ancient brick-making was documented by
Egyptian tomb paintings.
Wattle and daub is one of the oldest man-made composite
materials, at over 6000 years old.[2] Concrete is also a
composite material, and is used more than any other manmade material in the world. As of 2006, about 7.5 billion
cubic metres of concrete are made each yearmore than
one cubic metre for every person on Earth.[3]
2 EXAMPLES
Natural cement-stones, after burning, produced cements used in concretes from post-Roman times into
the 20th century, with some properties superior to
manufactured Portland cement.
Papier-mch, a composite of paper and glue, has
been used for hundreds of years
The rst articial bre reinforced plastic was
bakelite which dates to 1907, although natural polymers such as shellac predate it
One of the most common and familiar composite is
berglass, in which small glass ber are embedded
within a polymeric material (normally an epoxy or
polyester). The glass ber is relatively strong and Plywood is used widely in construction
sti (but also brittle), whereas the polymer is ductile (but also weak and exible). Thus the resulting
berglass is relatively sti, strong, exible, and ductile.
2
2.1
Examples
Materials
Concrete is the most common articial composite material of all and typically consists of loose stones (aggregate) held with a matrix of cement. Concrete is a very
robust material, much more robust than cement, and will
not compress or shatter even under quite a large compressive force. However, concrete cannot survive tensile loading (i.e., if stretched it will quickly break apart). Therefore, to give concrete the ability to resist being stretched,
steel bars, which can resist high stretching forces, are often added to concrete to form reinforced concrete.
Fibre-reinforced polymers or FRPs include carbon-berreinforced polymer or CFRP, and glass-reinforced plastic
or GRP. If classied by matrix then there are thermoplastic composites, short ber thermoplastics, long bre thermoplastics or long bre-reinforced thermoplastics. There
are numerous thermoset composites, but advanced systems usually incorporate aramid bre and carbon bre in
an epoxy resin matrix.
Shape memory polymer composites are highperformance composites, formulated using bre or
fabric reinforcement and shape memory polymer resin as
the matrix. Since a shape memory polymer resin is used
as the matrix, these composites have the ability to be
easily manipulated into various congurations when they
2.2
Products
3
neered laminate composites, such as Mallite, use a central
core of end grain balsa wood, bonded to surface skins of
light alloy or GRP. These generate low-weight, high rigidity materials.
2.2 Products
Fiber-reinforced composite materials have gained popularity (despite their generally high cost) in highperformance products that need to be lightweight,
yet strong enough to take harsh loading conditions
such as aerospace components (tails, wings, fuselages,
propellers), boat and scull hulls, bicycle frames and racing
car bodies. Other uses include shing rods, storage
tanks, swimming pool panels, and baseball bats. The
new Boeing 787 structure including the wings and fuselage is composed largely of composites. Composite materials are also becoming more common in the realm of
orthopedic surgery.
3 Overview
Composites are made up of individual materials referred
to as constituent materials. There are two main categories
of constituent materials: matrix and reinforcement. At
least one portion of each type is required. The matrix
material surrounds and supports the reinforcement materials by maintaining their relative positions. The rein-
4 CONSTITUENTS
inforcement before or after the reinforcement material is
placed into the mould cavity or onto the mould surface.
The matrix material experiences a melding event, after
which the part shape is essentially set. Depending upon
the nature of the matrix material, this melding event can
occur in various ways such as chemical polymerization or
solidication from the melted state.
A variety of moulding methods can be used according to
the end-item design requirements. The principal factors
impacting the methodology are the natures of the chosen
matrix and reinforcement materials. Another important
factor is the gross quantity of material to be produced.
Large quantities can be used to justify high capital expenditures for rapid and automated manufacturing technology. Small production quantities are accommodated with
lower capital expenditures but higher labour and tooling
costs at a correspondingly slower rate.
Many commercially produced composites use a polymer
matrix material often called a resin solution. There are
many dierent polymers available depending upon the
starting raw ingredients. There are several broad categories, each with numerous variations. The most common are known as polyester, vinyl ester, epoxy, phenolic,
polyimide, polyamide, polypropylene, PEEK, and others. The reinforcement materials are often bres but also
commonly ground minerals. The various methods described below have been developed to reduce the resin
content of the nal product, or the bre content is increased. As a rule of thumb, lay up results in a product
containing 60% resin and 40% bre, whereas vacuum infusion gives a nal product with 40% resin and 60% ber
content. The strength of the product is greatly dependent
on this ratio.
Martin Hubbe and Lucian A Lucia consider wood to be
a natural composite of cellulose bres in a matrix of
lignin.[5][6]
4 Constituents
4.1 Matrices
4.1.1 Resins
Carbon ber composite part.
Typically, most common polymer-based composite materials, including berglass, carbon ber, and Kevlar, include at least two parts, the substrate and the resin.
Polyester resin tends to have yellowish tint, and is suitable for most backyard projects. Its weaknesses are that
it is UV sensitive and can tend to degrade over time, and
thus generally is also coated to help preserve it. It is often
used in the making of surfboards and for marine applications. Its hardener is a peroxide, often MEKP (methyl
ethyl ketone peroxide). When the peroxide is mixed with
Engineered composite materials must be formed to the resin, it decomposes to generate free radicals, which
shape. The matrix material can be introduced to the re- initiate the curing reaction. Hardeners in these systems
4.3
Cores
are commonly called catalysts, but since they do not reappear unchanged at the end of the reaction, they do not
t the strictest chemical denition of a catalyst.
Vinylester resin tends to have a purplish to bluish to
greenish tint. This resin has lower viscosity than polyester
resin, and is more transparent. This resin is often billed
as being fuel resistant, but will melt in contact with gasoline. This resin tends to be more resistant over time to
degradation than polyester resin, and is more exible. It
uses the same hardeners as polyester resin (at a similar
mix ratio) and the cost is approximately the same.
Epoxy resin is almost totally transparent when cured. In
the aerospace industry, epoxy is used as a structural matrix material or as a structural glue.
Shape memory polymer (SMP) resins have varying visual
characteristics depending on their formulation. These
resins may be epoxy-based, which can be used for
auto body and outdoor equipment repairs; cyanate-esterbased, which are used in space applications; and acrylatebased, which can be used in very cold temperature applications, such as for sensors that indicate whether perishable goods have warmed above a certain maximum temperature. These resins are unique in that their shape can
be repeatedly changed by heating above their glass transition temperature (Tg). When heated, they become exible and elastic, allowing for easy conguration. Once they
are cooled, they will maintain their new shape. The resins
will return to their original shapes when they are reheated
above their Tg. The advantage of shape memory polymer
resins is that they can be shaped and reshaped repeatedly
without losing their material properties. These resins can
be used in fabricating shape memory composites.
Dierences in the way the bers are laid out give dierent
strengths and ease of manufacture
4.2
4.2.1
Reinforcements
Fiber
Steel mesh or wires are also used in some glass and plastic
products.
4.3 Cores
FABRICATION METHODS
honeycombs are commonly used core materials. Open- mandrel, etc. Continuous manufacturing uses a dierent
and closed-cell metal foam can also be used as core nomenclature.
materials.
The moulded product is often referred to as a panel. For
certain geometries and material combinations, it can be
referred to as a casting. For certain continuous processes,
5 Fabrication methods
it can be referred to as a prole.
Fabrication of composite materials is accomplished by a
5.2
wide variety of techniques, including:
5.1
Mold overview
5.5
and the ends sealed. One method of sealing the open ends
of the bag is by placing a clamp on each end of the bag.
A plastic rod is laid across the end of the bag, the bag is
then folded over the rod. A plastic sleeve with an opening
in it, is then snapped over the rod. This procedure forms
a seal at both ends of the bag, when the vacuum is ready
to be drawn.
5.3
5.7 Tooling
5.4
Autoclave moulding
The mold and mold inserts are referred to as tooling. The mold/tooling can be constructed from a variety of materials. Tooling materials include invar, steel,
aluminium, reinforced silicone rubber, nickel, and carbon
ber. Selection of the tooling material is typically based
on, but not limited to, the coecient of thermal expansion, expected number of cycles, end item tolerance, desired or required surface condition, method of cure, glass
transition temperature of the material being moulded,
moulding method, matrix, cost and a variety of other considerations.
force) in nature, but rather are typically anisotropic (different depending on the direction of the applied force or
load). For instance, the stiness of a composite panel will
often depend upon the orientation of the applied forces
and/or moments. Panel stiness is also dependent on the
design of the panel. For instance, the bre reinforcement
and matrix used, the method of panel build, thermoset
versus thermoplastic, type of weave, and orientation of
bre axis to the primary force.
In contrast, isotropic materials (for example, aluminium
or steel), in standard wrought forms, typically have the
same stiness regardless of the directional orientation of
the applied forces and/or moments.
The relationship between forces/moments and
strains/curvatures for an isotropic material can be
described with the following material properties:
Youngs Modulus, the shear Modulus and the Poissons
ratio, in relatively simple mathematical relationships.
For the anisotropic material, it requires the mathematics
of a second order tensor and up to 21 material property
constants. For the special case of orthogonal isotropy,
there are three dierent material property constants for
each of Youngs Modulus, Shear Modulus and Poissons
ratioa total of 9 constants to describe the relationship
between forces/moments and strains/curvatures.
Techniques that take advantage of the anisotropic properties of the materials include mortise and tenon joints (in
natural composites such as wood) and Pi Joints in synthetic composites.
REFERENCES
6.2 Testing
To aid in predicting and preventing failures, composites
are tested before and after construction. Pre-construction
testing may use nite element analysis (FEA) for plyby-ply analysis of curved surfaces and predicting wrinkling, crimping and dimpling of composites.[8] Materials may be tested during manufacturing and after construction through several nondestructive methods including ultrasonics, thermography, shearography and X-ray
radiography,[9] and laser bond inspection for NDT of relative bond strength integrity in a localized area.
7 See also
Aluminium composite panel
American Composites Manufacturers Association
Chemical vapour inltration
Epoxy granite
Nanocomposites
Hybrid material
6.1
Failure
Composite laminates
Rule of mixtures
Void (composites)..
Composite
8 References
[1] M. A. McEvoy and N. Correll. Materials that couple sensing, actuation, computation and communication. Science
347(6228), 2015.
[2] Shaer, G.D. An Archaeomagnetic Study of a Wattle and
Daub Building Collapse. Journal of Field Archaeology,
20, No. 1. Spring, 1993. 59-75. JSTOR. Accessed 28
January 2007
[3] Minerals commodity summary cement 2007. US
United States Geological Survey. 1 June 2007. Retrieved
16 January 2008.
[4] Heather Lechtman and Linn Hobbs Roman Concrete
and the Roman Architectural Revolution, Ceramics and
Civilization Volume 3: High Technology Ceramics: Past,
Present, Future, edited by W.D. Kingery and published
by the American Ceramics Society, 1986; and Vitruvius,
Book II:v,1; Book V:xii2
[5] http://www.ncsu.edu/bioresources/BioRes_02/BioRes_
02_4_534_535_Hubbe_L_BioResJ_Editorial_
LoveHate.pdf
[6] David Hon and Nobuo Shiraishi, eds. (2001) Wood and
cellulose chemistry, 2nd ed. (New York: Marcel Dekker),
p. 5 .
[7] Vacuum Bags For Woodworking.
[8] Waterman, Pamela J. The Life of Composite Materials.
Desktop Engineering Magazine. April 2007.
[9] Matzkanin, George A.; Yolken, H. Thomas. Techniques
for the Nondestructive Evaluation of Polymer Matrix
Composites (PDF). AMMTIAC Quarterly 2 (4).
Further reading
Robert M. Jones (1999). Mechanics of Composite Materials (2nd ed.). Taylor & Francis. ISBN
9781560327127.
Autar K. Kaw (2005). Mechanics of Composite Materials (2nd ed.). CRC. ISBN 0-8493-1343-0.
Handbook of Polymer Composites for Engineers By
Leonard Hollaway Published 1994 Woodhead Publishing
Matthews, F.L. & Rawlings, R.D. (1999). Composite Materials: Engineering and Science. Boca Raton:
CRC Press. ISBN 0-8493-0621-3.
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