Goal: Present an overview of composite materials

Objectives:
Application of composites in aerospace industry
Definition of composite
Introduction to matrix and fiber
Choice of material for aerospace structural applications
Illustration of advantages of using fiber reinforced composites

Key structural members made of composites

Control sufraces
Fuselage doors
hatches using sandwich and monolithic
construction
large wing skin panels / airbrake skins
Wing parts like spars etc.
(source: http://www.tejas.gov.in/technology/composite materials.html)

Department of Aerospace Engineering 2

. Indian Institute of Technology .
 Other aerospace applications

(source: image courtesy of Composites World)

Department of Aerospace Engineering 3

. Indian Institute of Technology .
 Other aerospace applications

(source:https://www.compositesworld.com/articles/donauwrth-as-composites-pioneer)

(source: image courtesy of Westland Helicopters)

Department of Aerospace Engineering 4

. Indian Institute of Technology .
 Other aerospace applications

Figure: Extruded Preforms

Figure: Products: Nozzle

Figure: Material architecture

Figure: Products: Nozzle Figure: Products: Nose Cap

(source: image courtesy of various web sources)

Department of Aerospace Engineering 5

. Indian Institute of Technology .
 Material modelling aspects

Analysis of Structure

Characterization Prohibitive, Large

set of Material Config.

Analytical methods

Micro-mechanical Analysis for

Characterization
Benefits
Analysis before Realization
Optimization of Material
Micro-geometry
(source: image courtesy of Tang an Yu (2017))

Department of Aerospace Engineering 6

. Indian Institute of Technology .
 Modeling composites: role of micromechanics

Definition
Study of heterogeneous composite
material behavior, based on the
behavior of constituent phases.

Features of Micro-mechanics
Multiphase material modeling
with complex micro-structures.
Arbitrary elastic/inelastic
constitutive model at individual
phase level
Closed-form constitutive
Figure: Role of Micro-mechanics
equations.
(source: image courtesy of Tang an Yu (2017))

Department of Aerospace Engineering 7

. Indian Institute of Technology .
 Modeling composites: role of micromechanics

Heterogeneity and Length Scales

If d is the microscopic length parameter and D is
the macroscopic length parameter such that
d
D << 1, the material is homogeneous at length
scale D and it is sufficient to consider the overall
properties.

Macroscopic Averages
Average Stresses and Strain in a domain D is
given by Z
1
σij = σij dV (1)
D D
Z
1
ij = ij dV (2)
D D
Figure: RVE and RUC [Pindera et al. (2009)]
(source: image courtesy of Tang an Yu (2017))

Department of Aerospace Engineering 8

. Indian Institute of Technology .
 Homogenization & Localization

Homogenization
Localization(global-local decomposition)
The basic idea of homogenization is the
replacement of a RUC/RVE of a Localization is the reverse of homogenization,
micro-heterogeneous solid by a homogeneous one where the micro-mechanics model is used to
which, from a macroscopical point of view recover the constituent ”behavior” inside the
behaves in the same manner as that of a RUC/RVE from the macro ”behavior” on the
heterogeneous solid. structure.

Micro-mechanical Methods
Rule of Mixture
Eshelby Method
Mori-Tanaka Method
Generalized Method of Cells(GMC)
Figure: Homogenization of RUC [Pindera et al.
(2007)] Variational Asymptotic Method(VAM)
(source: image courtesy of Tang an Yu (2017))

Department of Aerospace Engineering 9

. Indian Institute of Technology .
 What are composite materials?
Definition: Consist of two or more separate materials combined in a structural unit.
Main ingredients: matrix material and fillers
Matrix materials: metals and polymers
Fillers: fibers (macro/nano), particles, flakes etc.

Figure: Types of fillers

(source: image courtesy of Hull and Clyne, An introduction to composite materials)

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. Indian Institute of Technology .
 Why fiber configuration is a popular filler?
Materials and stronger and stiffer in fiber fiber form.
Geometrical shape is efficient from the point of view of interaction with the binder or matrix.
Disadvantages: cannot support compression and weak transverse mechanical properties.

Figure: Strength v/s size

Figure: Filler aspect ratio
(source: image courtesy of Gibson Principles of composite materials)

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. Indian Institute of Technology .
 Role of matrix

Necessary to hold or bind the fibers together as a structural unit

Protects the fibers from extermal damage and environmental attack
Transfers and distributes the load
Contributes to ductility, toughness and electrical insulation
Ex: polymers, metals and ceramics
Typical properties of a class materials

Material Density Young’s Tensile Fracture Thermal Thermal

modulus strength toughness conductivity expansivity
√
(Mg m−3 ) (GPa) (MPa) (MPa m) (W m−1 K−1 ) (10−6 K−1 )
Thermosetting resin (epoxy) 1.25 3.5 50 0.5 0.3 60
Engineering thermoplastic (nylon) 1.1 2.5 80 4 0.2 80
Rubber (polyurethane) 1.2 0.01 20 0.1 0.2 200
Metal (mild steel) 7.8 208 400 140 60 17
Construction ceramic (concrete) 2.4 40 20 0.2 2 12
Engineering ceramic (alumina) 3.9 380 500 4 25 8

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. Indian Institute of Technology .
 Material properties

Figure: Modulus and hardness

(source: image courtesy of Hull and Clyne, An introduction to composite materials)

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. Indian Institute of Technology .
 Material properties

Figure: Modulus v/s Density

Figure: Merit index
Property maps allows to conveniently compare the property combinations offered by matrices and
reinforcements with those of alternative conventional materials. (source: image courtesy of Hull and Clyne, An introduction
to composite materials)

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. Indian Institute of Technology .
 Typical properties of FRP composites compared to other materials

Material Specific gravity, S Young’s Tensile Compressive Specific Specific Specific

modulus strength Strength, Xc modulus tensile compressive
E Xt Xc E/S strength, Xt /S strength, Xc /S
(GPa) (MPa) (MPa)
Steel 7.8 206 400 - 2500 400 - 2500 26.4 50 - 320 50 - 320
Al alloy 2.8 69 55 - 700 55 - 700 24.6 20 - 250 20 - 250
Ti alloy 4.5 103 360 - 1400 360 - 1400 22.9 80 - 310 80 - 310
GFRP 2.0 40 1650 1400 20 825 700
CFRP 1.6 140 1450 1050 87.5 906.3 656.3

Selection of material is a key step in the process of structural design

Do we always select a material with superior material stiffness and strength? If so, why is steel not always
preferred?
How to approach material selection in weight sensitive designs?
Are there metrics/indices that one can quickly use to select materials when materials have conflicting material
characteristics?
Note: Properties listed in the table are not exhaustive and are only meant to convey an idea.

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. Indian Institute of Technology .
 Performance index

Strength design: ultimate strength/density − > Xt/c /ρ

q
E
Stiffness design: ρ
E
Buckling design: ρ3

Material Strength design Stiffness design Buckling design

103 m2 /sec2 103 m/sec m8 /kg2 sec2
Steel 320 5.13 0.43
Al alloy 250 4.96 3.14
Ti alloy 311.1 4.78 1.13
GFRP 825 4.47 5
CFRP 906.25 9.35 34.18

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. Indian Institute of Technology .
 Weight saving: an example

A cantilever beam of rectangular cross-section and made of Al alloy is to be replaced by a CFRP

beam having the same length ’L’ and width ’b’, and it must have the same tip deflection ’w’ under
the same tip load ’P’. Compare the thicknesses and weights of the two beams. Material properties
for the two materials are given below.

Material Specific gravity, S Young’s Tensile Compressive Specific Specific Specific

modulus strength Strength, Xc modulus tensile compressive
E Xt Xc E/S strength, Xt /S strength, Xc /S
(GPa) (MPa) (MPa)
Al alloy 2.8 69 55 - 700 55 - 700 24.6 20 - 250 20 - 250
CFRP 1.6 140 1450 1050 87.5 906.3 656.3

Department of Aerospace Engineering 17

. Indian Institute of Technology .