PEMP

EMM2512

Session Objectives

At the end of the session the delegates will be

able to understand
What are composites?
Classification
Properties
Applications of composites

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What are Composites?

 Composite is a combination of two or more chemically
distinct and insoluble phases
 Constituent materials or phases must have significantly
different properties for it to combine them: thus metals and
plastics are not considered as composites although they have
a lot of fillers and impurities
 The properties and performance of composites are far
superior to those of the constituents
 Composites consist of one or more discontinuous phases
(reinforcement) embedded in a continuous phase (matrix)
• Examples:
– Cemented carbides (WC with Co binder)
– Rubber mixed with carbon black
– Wood (a natural composite as distinguished from a synthesized
composite)
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Some examples of composite materials: (a) plywood is a laminar

composite of layers of wood veneer, (b) fiberglass is a fiber-reinforced
composite containing stiff, strong glass fibers in a softer polymer
matrix (× 175), and (c) concrete is a particulate composite containing
coarse sand or gravel in a cement matrix (reduced 50%).
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Merits of Composite Materials

Composites can be very strong and stiff, yet very light in weight, so
ratios of strength-to-weight and stiffness-to-weight are several times
greater than steel or aluminum

High specific strength and

High specific stiffness Long fatigue life
High creep resistance
Low coefficient of thermal expansion
Low density
Low thermal conductivity
Better wear resistance
Improved corrosion resistance
Better temperature dependent behavior

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Disadvantages and Limitations of

Composite Materials
• Properties of many important composites are
anisotropic - the properties differ depending on the direction
in which they are measured – this may be an advantage or a
disadvantage
• Many of the polymer-based composites are subject to attack
by chemicals or solvents, just as the polymers themselves are
susceptible to attack
• Composite materials are generally expensive
• Manufacturing methods for shaping composite materials are
often slow and costly

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Functions of the Matrix Material

(Primary Phase)
• Provides the bulk form of the part or product made of the
composite material
• Holds the imbedded phase in place, usually enclosing and
often concealing it
• When a load is applied, the matrix shares the load with the
secondary phase, in some cases deforming so that the stress
is essentially born by the reinforcing agent
• Cermets
– Ceramic (up to 90%) contained in a metallic matrix
– Cemented Carbides (tungsten, titanium, chromium)
– Cutting Tools, Dies, Indenters
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Classification
Based on the type of matrix material
• Polymer Matrix Composites (PMCs)
• Metal Matrix Composites (MMCs)
• Ceramic Matrix Composites (CMCs)
• Carbon/Carbon Composites (C/Cs)
Based on the geometry of reinforcement
• Particulate reinforced Composites
• Whisker/Flakes reinforced composites
• Fiber reinforced composites
Hybrid: A composite laminate comprising of laminae of two
or more composite material systems or a combination of two
or more different fibers such as C and glass or C and aramid
into a structure
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Based on the Type of Matrix

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Polymer Matrix Composites

(PMCs)
Are prominent class of composites compared to other composite
materials in commercial applications
Fiber Materials: Boron, Graphite, Carbon
Most of the PMCs use either carbon-graphite or aramid fibers, which
are the main commercial fibers
Matrix Materials:
Thermoplastic, Epoxy and Thermo-set materials.
•Thermoplastics offer the advantages of good mechanical and
tribological properties.
•Epoxy resin remains the most important matrix polymer.
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Metal Matrix Composites (MMCs)

•MMCs are advanced class of structural materials
consisting of nonmetallic reinforcements incorporated
into the metallic matrix.
•MMCs are widely used in engineering applications
where the operating temperature lies in between 250 ºC
to 750 ºC.
Matrix materials: Aluminum, Titanium, Copper,
Magnesium and Super alloys.
Reinforcement materials: Silicon carbide, Boron,
Molybdenum and Alumina
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Ceramic Matrix Composites

(CMCs)

CMCs are advanced class of structural materials consisting of

metallic/non-metallic reinforcements incorporated into the ceramic
matrix

CMCs are widely used in engineering applications where the operating

temperature lies in between 800ºC to 1650ºC

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Carbon/Carbon Composites (C/Cs)

C/Cs are developed specifically for parts that must operate in
extreme temperature ranges.
Composed of a carbon matrix reinforced with carbon yarn fabric,
3-D woven fabric, 3-D braiding, etc.
Applications: C/C composites meet applications ranging from
rockets to aerospace because of their ability to maintain and even
increase their structural properties at extreme temperatures.
Advantages:
Extremely high temperature resistance (1930°C – 2760°C).
Strength actually increases at higher temperatures (up to
1930°C).
High strength and stiffness.
Good resistance to thermal shock.

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Operating Temperatures EMM2512

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Classification Based on Reinforcement

Strengthening mechanism depends strongly on the

geometry of the reinforcement

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Types of Reinforcements
• Fibers
– Cross-section can be circular, square or hexagonal
– Diameters -- 0.0001” - 0.005 ” (0.00025-0.0125cm)
– Lengths -- L/D ratio
• 100 -- for chopped fiber
• Much longer for continuous fiber
• Particulate
– Small particles that impede dislocation movement (in metal
composites) and strengthens the matrix
– For sizes > 1 µm, strength of particle involved in load sharing
with matrix
• Flakes
– Flat platelet form

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Types of Reinforcement

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E-Glass S-Glass

Kevlar Graphite

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Other Composite Structures

• Laminar composite structure – conventional
• Sandwich structure
• Honeycomb sandwich structure

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Laminate:
A laminate is a layered
construction of a number
of lamine arranged in a
proper sequence.
The layers are stacked and
subsequently cemented
together such that the
orientation of fiber
direction (θ) varies with
each successive layer.
Lamine

Stacking sequence

Laminate [26]

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Other Laminar Composite Structures

• Automotive tires - consists of multiple layers bonded
together
• FRPs - multi-layered fiber-reinforced plastic panels for
aircraft, automobile body panels, boat hulls
• Printed circuit boards - layers of reinforced plastic and
copper for electrical conductivity and insulation
• Snow skis - composite structures consisting of layers of
metals, particle board, and phenolic plastic
• Windshield glass - two layers of glass on either side of a
sheet of tough plastic

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Sandwich Panel
High Strength
Composite Laminate Facing

Film Adhesive

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High Strength
Composite Laminate Facing

Film Adhesive

Low Density Honeycomb Core

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Types of Reinforcement Materials for Composites

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Properties of Composite Materials

• In selecting a composite material, an optimum
combination of properties is usually sought, rather
than one particular property
– Example: fuselage and wings of an aircraft must
be lightweight and be strong, stiff, and tough
• Several fiber-reinforced polymers possess this
combination of properties
– Example: natural rubber alone is relatively weak
• Adding significant amounts of carbon black to NR
increases its strength dramatically

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Comparison of the yield

strength of dispersion-
strengthened sintered
aluminum powder (SAP)
composite with that of two
conventional two-phase high-
strength aluminum alloys.
The composite has benefits
above about 300°C. A fiber-
reinforced aluminum
composite is shown for
comparison.

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Properties of Composites
 Particles and flakes usually enhance properties less
effectively than chopped fibers.
 Continuous fibers are the most effective, although the
properties vary with direction and are the strongest in the
longitudinal direction of the fiber -To reduce directionality,
woven mats and different plies are used
 A strong bond between the matrix and reinforcement phases.
 Properties are determined by three factors
– The materials used as component phases in the composite
– The geometric shapes of the constituents and resulting structure of the
composite system
– The manner in which the phases interact with one another

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Rule of Mixtures

Ec = EmVm + EpVp
Or Ec = EmEp/(EmVm + EpVp)
where Vm & Vp are the volume fraction of matrix and reinforcement respectively
and Em & Ep are elastic modulus of matrix and reinforcement
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Variation in elastic modulus and tensile strength as a function of

direction of measurement relative to longitudinal axis of carbon
fiber-reinforced epoxy composite

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Specific Strength and Modulus of Composites

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A three-dimensional weave
for fiber-reinforced
composites.
Effect of fiber orientation on the
tensile strength of E-glass fiber-
reinforced epoxy composites.
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Applications of PMCs

• Most widely used form of FRP is a laminar structure, made

by stacking and bonding thin layers of fiber and polymer
until desired thickness is obtained
• By varying fiber orientation among layers, a specified level
of anisotropy in properties can be achieved in the laminate
• Applications: parts of thin cross-section, such as aircraft
wing and fuselage sections, automobile and truck body
panels, and boat hulls
– Aerospace Industries (Carbon/Epoxy PMCs)
– Automobile Industry (Epoxy based PMCs)
– Springs and bumper systems (Reinforced Thermosets)
– Tooling (Epoxy based PMCs)
– Fiberglass reinforced plastic has been used for boat hulls, fishing
rods, tennis rackets, golf club shafts, helmets, skis, bows and arrows
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Applications
Space craft: Antenna structures, Solar reflectors, Satellite structures,
Radar, Rocket engines, etc.
Aircraft: Jet engines, Turbine blades, Turbine shafts, Compressor
blades, Airfoil surfaces, Wing box structures, Fan blades, Flywheels,
Engine bay doors, Rotor shafts in helicopters, Helicopter
transmission structures, etc.
Miscellaneous: (1) Bearing materials, Pressure vessels, Abrasive
materials, Electrical machinery, Truss members, Cutting tools,
Electrical brushes, etc.
(2) Automobile: Engines, bodies, Piston, cylinder, connecting rod,
crankshafts, bearing materials, etc.

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Light Weight Application

• Composites are the candidate materials
• Automotive body parts by composites mainly CFRP
and GFRP
• GFRP, CFRP, SMC, C/C for seat structures
• Formula one uses CFRP extensively
• CFRP is used in road and mountain bikes and also
in road bikes made of Al the seat posts handle bars,
and forks
• CFRP and Honeycomb composites for Chassis
• Fuel tanks made up of Kevlar reinforced rubber
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CFRP Application
web.missouri.edu/~smith
doug/nsf/presentations/

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Composites in a Boeing 777

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Composite Materials for Wind Turbine

Blades

CFRP Sonar Dome

The NEG-Micon 40 m radius AL40
carbon-wood epoxy wind turbine blade:
Resin infusion manufacturing process
www.tech.plym.ac.uk/sme/mats324

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Typical Cross section of a Wind Turbine Blade

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MMCs

www.youtube.com/watch?v=x
bPxVws5Ty4&feature=related

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Cemented Carbide
• One or more carbide
compounds bonded in a
metallic matrix
• Common cemented
carbides are based on
tungsten carbide (WC),
titanium carbide (TiC), and
chromium carbide (Cr3C2)
• Tantalum carbide (TaC)
and others are less common
• Metallic binders: usually Photomicrograph (about 1500X)
cobalt (Co) or nickel (Ni) of cemented carbide with 85%
WC and 15% Co
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Hardness vs. Transverse Rupture Strength

Typical plot of hardness and transverse rupture strength as a
function of cobalt content

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Applications of Cemented Carbides

• Tungsten carbide cermets (Co binder) - cutting tools are
most common; other: wire drawing dies, rock drilling bits
and other mining tools, dies for powder metallurgy,
indenters for hardness testers
• Titanium carbide cermets (Ni binder) - high temperature
applications such as gas-turbine nozzle vanes, valve seats,
thermocouple protection tubes, torch tips, cutting tools for
steels
• Chromium carbides cermets (Ni binder) - gage blocks,
valve liners, spray nozzles, bearing seal rings

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Summary
 Classification of composites have been
studied.
 The variation of mechanical properties with
reinforcement composition and direction is
addressed
 Advantages of composites are discussed.
 Applications of composite materials have
been addressed

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