Mod 1
Mod 1
MATERIALS
NIVIN VINCENT
DEPARTMENT OF MECHANICAL ENGINEERING
RSET
ALL ARE NOT COMPOSITES
• Many of common materials (metal alloys, doped Ceramics and Polymers mixed
with additives) also have a small amount of dispersed phases in their structures,
however they are not considered as composite materials since their properties
are similar to those of their base constituents (physical properties of steel are
similar to those of pure iron)
• Plastics – two different constituents are mixed at macroscopic level but there is
no significant changes in properties compared to its constituents.
• Alloys – there is significant improvement in some of the properties but they are
mixed at microscopic level.
• Composites are having physically distinct phases with distinct
properties
COMPOSITES IN NATURE
In the 1800s ,Canoe builders would layer wood pulp paper known
as kraft paper with a glue-like material known as shellac. However,
this paper laminate did not last long when submerged in water.
• Shortly after the 1870s and 1890s man-made, or synthetic, resins were
invented. These resins could transform from liquid to solid by cross-linking
molecules through a process known as polymerization.
• The evolution of resin and the use of polymerization continued into the
early 1900s where the curing (hardening) properties of unsaturated
synthetic resins lead to early plastics
RISE OF PLASTICS
• In the early 1930s, two U.S. chemical companies, American Cyanamid and
DuPont, further developed polymer resins. In the course of their
experimentation, both companies independently formulated polyester
resin for the first time.
Transformation from plastics to
composites
• In 1935, an incredible change occurs in the plastics
world. Owens Corning, a composites and glass company,
invented a glass fiber known today as fiberglass.
The Story of Fiberglass, Pt. 2 - Making the Plastic Corvette - Corvette Report
APPLICATION OF COMPOSITES
• Aerospace
• Marine
• Automobile
• Défense and communication
• Safety equipments
• Buildings and infrastructures
• Medical industry
• Sports
MARINE APPLICATION
• Composite materials have been used in the marine industry for a number of
years. The more traditional applications for composites include gratings, ducts,
shafts, piping, hull shells, etc for several decades.
• Composites make up more
than 20% of the A380's airframe.
AEROSPACE
DEFENSE AND COMMUNICATION
MEDICAL INDUSTRY
• For example, adjacent wood sheets in plywood are aligned with the grain direction at
right angles to each other.
• Laminations may also be constructed using fabric material such as cotton, paper, or
woven glass fibers embedded in a plastic matrix.
Sandwich composite
• Class of structural composites, are designed to be light-weight beams or panels having relatively
high stiffnesses and strengths
• A sandwich panel consists of two outer sheets, or faces, that are separated by and adhesively
bonded to a thicker core
• The outer sheets are made of a relatively stiff and strong material, typically aluminum alloys, fiber-
reinforced plastics, titanium, steel, or plywood
• They impart high stiffness and strength to the structure, and must be thick enough to withstand
tensile and compressive stresses that result from loading
• The core material is lightweight, and normally has a low modulus of elasticity
• Core materials typically fall within three categories: rigid polymeric foams (i.e., phenolics, epoxy,
polyurethanes), wood (i.e., balsa wood), and honeycombs
• Structurally, the core serves several functions
• It provides continuous support for the faces
• In addition, it must have sufficient shear strength to withstand
transverse shear stresses, and also be thick enough to provide high
shear stiffness (to resist buckling of the panel)
Interface and type of
bonding
• An interface between a reinforcement and a matrix as the bounding surface
between the two constituents across which a discontinuity in some parameter
occurs.
• An interface is the region through which material parameters, such as
concentration of an element, crystal structure, atomic registry, elastic modulus,
density, coefficient of thermal expansion, etc., change from one side to another
• The discontinuity across the interface may be sharp or gradual
• Interface between phases in a composite material:
• Direct bonding between primary and secondary phase
• Addition of a third ingredient to bond primary and secondary phases(forming
an interphase between them)
• The behavior of a composite material is a result of the combined behavior of the
following three entities:
• Fiber or the reinforcing element,
• Matrix, and
• Reinforcement/matrix interface
• The fiber surface area is essentially the same as the interfacial area
• Ignoring the fiber ends, one can write the surface-to-volume ratio (S/V) of the
fiber as
𝑆 2𝜋𝑟𝑙
=
𝑉 𝜋𝑟 2 𝑙
where r and l are the fiber radius and length of the fiber, respectively.
• Thus, the surface area of a fiber or the interfacial area per unit volume increases
as r decreases
• The applied load should be effectively transferred from the matrix to the fibers
via the interface.
• The interfacial zone, consists of near-surface layers of fiber and matrix and any
layer(s) of material existing between these surfaces
• Wettability of the fiber or any other reinforcement by the matrix and the type of
bonding between the two components constitute the primary considerations.
• Additionally, one should determine the characteristics of the interface and how
they are affected by temperature, diffusion, residual stresses
Wettability
• The ability of a liquid to spread on a solid surface.
• We can measure the wettability of a given solid by a liquid by considering the
equilibrium of forces in a system consisting of a drop of liquid resting on a plane,
solid surface in the appropriate atmosphere
• The liquid drop will spread and wet the surface only if this results in a net reduction
of free energy of the system
• Wettability describes the extent of intimate contact between a liquid and a solid
• During the manufacturing process, the matrix is often behaving as liquid like
condition.
• Good wetting means that liquid(matrix) will flow over reinforcement, covering all
bumps and dips of the reinforcement surface
• Interfacial bonding exists due to the adhesion between reinforcement and
matrix(if wetting is good)
• The contact angle, can be measured directly by a goniometer or calculated by
using simple trigonometric relationships involving drop dimensions
• Young’s equation:
𝛾𝑆𝐿 = 𝛾𝐿𝑆 + 𝛾𝐿𝑉 cos 𝜃
• where 𝛾 is the specific surface energy and the subscripts SV, LS, and LV represent
solid/vapor, liquid/solid, and liquid/vapor interfaces, respectively
Contact angle goniometer
• A low contact angle, meaning good wettability, is a necessary but not sufficient
condition for strong bonding
• To obtain an intimate contact between the fiber and the matrix, the matrix in
liquid form must wet the fiber
• Coupling agents are frequently used to improve the wettability between the
components.
• Other approaches, such as modifying the matrix composition, are used
Interfacial Bonding
The important types of interfacial bonding as follows:
• Mechanical bonding,
• Physical bonding,
• Chemical bonding,
– Dissolution bonding, and
– Reaction bonding
• Mechanical bonding
• Simple mechanical keying or interlocking effects between two
surfaces can lead to a considerable degree of bonding.
• In a fiber reinforced composite, any contraction of the matrix onto
a central fiber would result in a gripping of the fiber by the matrix
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Structural smart composites