UNIT II COMPOSITE

Introduction to composites – Characteristics, Matrix materials – Types

– Polymer matrix, metal matrix, ceramic matrix, carbon and graphite
matrix material. Reinforcement – fiber, particulates, flakes and
whiskers, Classification of composites – Particulates, fibrous and
laminated composites – Hybrid composites – Application of
composites in electrical and electronic component
Composites
A material which is composed of two or more materials at a microscopic scale and have
chemically distinct phases
Heterogeneous at a microscopic scale but statically homogeneous at macroscopic scale
Constituent materials have significantly different properties
Components which are made to form composites are mutually insoluble and form distinct
phases
properties of composites are determined by properties, amount, shape and size of the
constituents
Ex : Reinforced Concrete Cement (RCC) – steel is reinforced into concrete mixture to give strength
Ball – rubber is embedded between cellulose material (cotton) to give more strength to rubber
Natural composites
Peanut husk, banana skin
Wood – a strong and flexible
cellulose is surrounded
by soft protein, collagen
Why do we need composite materials?
• Strength
• Stiffness
• Toughness
• Corrosion resistance
• Wear resistance
• Reduced weight
• Fatigue life
• Thermal/Electrical insulation and conductivity
• Acoustic insulation
• Energy dissipation
• Attractiveness, cost
•Tailorable properties
Advantages
• High strength, stiffness, toughness
• Low electrical conductivity, thermal expansion
• Corrosion and oxidation resistance
• Reduced weight
• Applications
• Electronic circuit boards (PCB)
• Marine, aeronautical applications
• High temperature refractories
History
4000 B.C. – laminated writing material from the papyrus plant
1300 B.C. – Egyptians and Mesopotamian used straw bricks
1200 A.D. - Mongols invented the first composite bow
Composite Bow – dates back to 3000 BC (Angara Dating)
Materials Used:
Wood, Horn, Sinew (Tendon), Leather, Bamboo and Antler (Deer horn)
Horn and Antler: naturally flexible and resilient Strings: Sinew, Horse hair, Silk

Sinews: back tendons or

hamstrings of cows and deer

Glue: From bladder of fish

Evolution of materials
Constituents of composites https://www.youtube.com/watch?v=SFMkdmfwjcg

Composite

Dispersed phase
Matrix
(Reinforced agent)

Carbon
Metal Polymer Fibre Particulates Flakes Whiskers
Ceramic and
graphite

https://www.youtube.com/watch?v=wUp9Yl6-QBM https://www.youtube.com/watch?v=2XikANkR8D0 - Flange

https://www.youtube.com/watch?v=aVtcv0jpcHE - FRP, Tank
Matrix
• Contribute bulk of the composite, encloses the composite
• Binds the dispersed phase
• Distribute the applied external load to the dispersed phase
• Protects the dispersed phase from chemical action, abrasion from environment
• Prevents the propagation of brittle cracks due to its plasticity and softness
Requirements
• Ductile and corrosion resistant
• High bonding strength between matrix phase and disperse phase
Dispersed phase
• Stronger and harder, determines the internal structure of composite
• Contribute desired properties
• Responsible for load carrying and transfer strength to matrix
https://www.youtube.com/watch?v=G4DlsYgmVnk - manufacturing processes
https://www.youtube.com/watch?v=pi5rxhHBx9o
I. Fibre reinforced composites
It consists of filament (high tensile strength/specific gravity), matrix and bonding agent (binds
disperse phase to matrix)
It has high aspect ratio (ratio of its width to its height), stiffness and specific modules
Shape, orientation and composition of fibre decide property of composites

Fibre

Organic (low density, flexibility and Inorganic (high modulus, high

elasticity) thermal stability)

Polyester Natural Ceramic

Aramid Carbon (cotton, Glass Boron Metallic
jute, hemp) fibre
Examples for Fibre reinforced polymer (FRP)
1. Glass fibre reinforced polymer(matrix)
The earliest known fibre
The polymer can be either thermoplastic or thermosetting
Glass fibre is used for improving the characteristics of polymer matrices – nylon, polyester, etc.,
Possesses lower density, high tensile strength, resistance to corrosion and chemicals
Applications
Automobile parts, storage tanks, plastic pipes, etc.,
Disadvantages
Prone to breakage when subjected to high tensile stress for long time
Glass is made up of a complex mixture of silicon dioxide and other oxides, such as
calcium, sodium, potassium, aluminum, and boron. The composition of these oxides
determines the glass's properties, including its transparency, rigidity, temperature
resistance, conductivity, and biocompatibility
2. Carbon fibre reinforced polymer
Dispersed phase – graphite, Matrix- polymer
Gives excellent resistance to corrosion
Lighter density, stiffest fibres
Properties of graphite remain unchanged even at very high T
Applications
Structural components of aircraft and helicopters, bicycle, motorcycle
Sports materials – tennis racket
Musical instruments strings
Disadvantage
Highly expensive
3. Aramid fibre reinforced polymer
Aramid is a synthetic fibre made from the polymer aromatic polyamide
It was first introduced in the 1960s as a meta-aramid and later as para-aramid
Meta-aramid bonds are not aligned but are rather in a zigzag pattern and therefore will not
develop the higher tensile strength (Tensile strength is a material's maximum capacity to withstand
mechanical tensile stress before it fails) of para-aramid bonds
The trademark names of aramid fibres are Kevlar (para) and Nomex (meta)
Kevlar is a manufactured plastic made through a condensation reaction between
1,4-phenylene-diamine (para-phenylenediamine) and terephthaloyl chloride:
Properties
A high heat, fire resistance and strong synthetic fibre
Density is less than glass and graphite fibres
High tensile strength, high modulus of elasticity (Modulus of elasticity, also known as elastic modulus, is a
measure of a material's resistance to deformation and its stiffness), low weight and non conductive fibre
Good resistance to abrasion
But sensitive to acids, alkali and UV radiation
Applications
Making of helmets, hockey sticks, tennis strings and asbestos replacement
4. Alumina reinforced polymer (matrix) composite
Improved stiffness, abrasion resistance and creep resistance ( material's ability to withstand
deformation under stress over a long period of time).
Used for making components of turbine engines
Offers good compressive strength rather than tensile strength in automobiles
5. Metal reinforced composites
Dispersed phase – alloys of Al, Mg, Cu, Ti with 20 -50 % of C, SiC, B, etc., Matrix (polymer)
Used at high T, possess high strength
Easily handled unlike glass fibre
Used in aerospace and new engine applications
Steel wire is the most extensively used fibre
6. Ceramic (clay) (SiC) reinforced composites
Known as Cermites (ceramic (dispersed )+ metal (matrix))
Ex : (i)TiC embedded in a matrix of a metal – Co or Ni,
(ii)Ceramic refractory carbide (WC) with Co or Ni
Applications
As cutting tools for hardened steel
As both matrix and dispersed phase are refractory, they can withstand high T generated due to
friction during cutting action on the hard materials
II. Particulates
Small pieces of hard solid material (metallic/non-metallic) ranging from microscopic to
macroscopic
Distribution is uniform throughout making it isotropic (material properties same in all directions)
composite
Function
Increase surface hardness
Cause constraint (retard) on plastic deformation
Increases performance at elevated temperature,
abrasion resistance and strength
Thermal and electrical conductivities are modified
Decrease shrinkage and friction
Decrease cost of composite
Ex : Laminate composite : Capacitors – alternating layers of an insulator and a conductor
Conductivity in parallel plates (Al) and insulation in perpendicular direction (mica)
Particulates can be mixed with matrix in the form of metal (Al alloy), polymer (rubber), Ceramic (concrete)
Particulates can be classified into two types based on size range.
i) Large particle (1 – 50 𝜇𝑚) ii) Dispersion strengthened ( < 0.1 𝜇𝑚)
i) Cermets – ceramic particle (dispersed phase) (strong and brittle) in a metal matrix
(WC & TiC + Co/Ni)
Used for cutting tools for hardened steel

ii) Vulcanized rubber - natural rubber with S and

other curatives (matrix)
Strengthened with 20 – 50 nm carbon black particles(dispersed)
iii) Concrete : matrix – cement and water
Dispersed phase is sand and pebbles
The function of sand pebbles is to increase the modulus of matrix, decrease permeability and ductility of
matrix
b. Dispersion strengthened ( < 0.1 𝜇𝑚)
Can be carbides, oxides, borides
Ex : sintered( material has been formed into a solid mass using heat or pressure without melting it) Al powder (fine Al2O3 in
pure Al matrix)
Ductile matrix + hard particle using powder metallurgy, composite is formed
This oxide prevents grain growth and movement of dislocations at the boundaries or through
them and produces high strength, high creep resistance and insensitivity to high-temperature
exposure
Particles distribution in a matrix
III. Flakes
Thin, flat solid having 2D geometry, placed in a matrix
Ex : mica and glass
Flakes provide –
Uniform mechanical properties in the plane of the flakes
Higher strength, flexural modulus (tendency of a material
to undergo bending, resistance to elasticity)
Higher dielectric strength(maximum electric field) and heat resistance
Better resistance to penetration by liquid and vapour
Lower cost compared to fibre
Often used in place of fibre
Metal flakes that are in close contact with each other in polymer can conduct electricity and heat
while mica and glass flakes resist both
IV. Whiskers
A thin strong filament or fibre made by growing as crystals or single crystal grown with nearly
zero defects
High L/D ratio and strongest known material but its usage is restricted due to its cost and
difficulty in incorporation
Usually discontinuous and short fibres of different cross section
Ex : Graphite, SiC in ceramic matrix and SiC in Al (used in automobiles)
Properties depend on distribution, orientation and geometry of whisker void content
Smaller void content gives low susceptibility to weathering
Higher void content increases thermal and insulating properties
Classification of composites

Composite

Particulate Structural
Fibrous composite
composite Composite

Large Dispersion Continuous

Discontinu Sandwich
long Laminates
particle strengthened (aligned) ous (short) panels

Randomly
Aligned
oriented
II. Fibre reinforcement
a. Continuous
The fibres are long and strength of the composite depends upon the direction of the fibre in
which they are aligned

If oriented to one direction ie longitudinal direction, more strength will be present along this
direction
b. Discontinuous
Fibres are short. Generally fibres are randomly arranged
Ex for fibres : polymer, metal, ceramic
Mechanical properties are isotropic
Have low strength than continuously arranged fibres

Woven, aligned and randomly oriented

III. Structural composites
a. Laminar
Composed of 2D sheets or panels that have a preferred high strength direction such as
plywood
Layers are stacked and cemented together such that the orientation of high strength direction
varies with each successive layer
b. Sandwich panel
Consists of two strong outer sheets called faces separated by a layer of less dense material,
called core
Ex : Foam material
Advantages
Light weight and large bend stiffness
Matrix phase
I. Polymer matrix
The most ideal matrix because it can be easily processed and produces light weight composite
Gives desirable mechanical properties
Polymer distributes the load uniformly to the dispersed phase
Protects surface of the composite against abrasion, wear & tear and corrosion, etc.,
a. Thermoplastic matrix
Ex : PE, PS, PP, Nylon, Polyamide, PC, etc.,
Can be easily processed, recycled and
high damage tolerance characteristics
Disadvantages
Larger degree of expansion and contraction
Undergo deterioration at elevated T
Absorption of moisture in humid environment
b. Thermosetting matrix
Ex : polyester resin, epoxy, phenolic resin, PU, Silicone, polyamide, etc,.
Provides strength, resistance to creep(mechanical stress), good modulus(resistance to elasticity)
Disadvantage : due to cross linking, it exhibits brittleness
i) Polyester resin
Cheap and widely used matrix
Liquid polyester can be stored at RT for several months or year
Addition of a catalyst can cure matrix within a short time
Cured polyester is rigid, transparent and stable against chemicals
Fibre glass reinforced polyester
Easily compatible with glass fibre
Used in automobile and structural applications
ii) Epoxy resin
Good mechanical properties
Reasonably stable to chemical attack
Excellent adherent property
Low shrinkage during curing and no emission
of volatile gases
Can’t be used beyond 140 o C, highly expensive
iii) Phenolic resin
Withstand high T and stable to chemical attack
Used for structural applications (roof, aircraft interior, etc.,)

Problems with polymer matrix

• Limited temperature range
• Susceptibility to environmental degradation due to
moisture, radiation, atomic oxygen (in space)
• Low transverse strength (load bearing capacity at centre
or ends)
• High residual stress due to large mismatch in
coefficients of thermal expansion both fiber and matrix
• Polymer matrix can not be used near or
above the glass transition temperature Phenolic resin cotton fabric laminated
II. Metal matrix Composite (MMC)
Most widely used matrix because they are resilient (able to recoil) and plastically deformed and
strengthened easily or spring back into shape after bending/stretching
Important MMC
i) Al with B, SiC, Al2O3, graphite
ii) Mg with graphite, Al2O3
iii) Ti with SiC, coated B
iv) Cu with graphite, SiC
Reinforcement surface is coated to prevent
a chemical reaction with the matrix
Mainly used in automobile and space shuttle
Advantage
• Use at higher temperature range
Aluminium matrix composite – use temperature range above 300 o C and titanium at 800 oC
• Higher transfer strength, toughness (in contrast with brittle behaviour of polymers and
ceramics)
• The absence of moisture & high thermal conductivity (copper)
Disadvantages
• Heavier
• More susceptible to interface degradation at the
fiber/matrix interface and to corrosion
III. Ceramic matrix (CMC)
is an inorganic, non metallic, often
crystalline oxide, nitride, carbide
Withstand at high T (1000 – 1600 o C)
Consists of a ceramic fibre embedded in a
ceramic matrix
Ceramic materials exhibit high physical and
mechanical properties – high refractoriness
but their applications are restricted to their
brittleness
Therefore a ceramic is reinforced into
another ceramic matrix
Ceramic matrix composites are reinforced
by either continuous (long) or
discontinuous
Ceramic matrix with continuous and discontinuous fibre
Continuous fibre Discontinuous fibre
Fabricated by chemical vapour Prepared by
deposition of SiC on a substrate matrix (Al2O3, SiC) with
made of W or Carbon fibre whiskers of SiC, Titanium boride
Not catastrophic (TiB2),
High mechanical strength even AlN, ZrO2
at high T
High thermal shock resistance Disadvantage is damages may
Low density, high corrosion occur during working
resistance at high T (catastrophic)
• Ex: SiC – filter for hot liquids,
gas fired burner part
• Mullite (Al2O3 – Al2O3 &
SiO2)
Manufacturing of heat
exchanger
• Carbon – carbon : refractory
components
Applications of CMC
IV Carbon matrix composite
Both matrix and dispersed phase are carbon
Woven mesh of carbon fibres – used for chemical filtration and separation
Light weight and can withstand T up to 3000 o C
Structure can be tailored to meet requirements
Used for high strength and modulus of rigidity
Advantages
• Low specific weight
• High heat absorption capacity
• Resistance to thermal shock
• High resistance to damage
• Exceptional frictional properties at high energy levels
• Resistance to high temperatures
• Chemical inertness
• low coefficient of thermal expansion (excellent dimensional stability)
Disadvantages
• low resistance to oxidation above 500°C
• high cost of materials and manufacturing
Applications
Hybrid composites
Two or more fibres are incorporated within a single matrix
Between two fibres one is generally organic and another is inorganic in nature
Classification
Based on the possible interactions connecting the two fibres
Class I - Hybrid materials are those that show weak interactions between the two phases – van
der waals, H-bonding, electrostatic attraction
Class II - Connected by strong chemical interactions between them –covalent bond
Advantages
Inorganic clusters or nanoparticles with specific optical, electronic and magnetic properties can
be incorporated in organic polymer matrices
Applications
Scratch resistance coating with hydrophobic or anti fogging properties (chemicals that prevent
condensation of water)
Nanocomposite devices for electronic and opto electronic applications – LED, photodiodes, solar
cells, gas sensors, etc.,
Fire retardant materials for construction industry (epoxy polymer or aromatic compound with
hetero atom) + fibre (Glass, Aramide)
Composite electrolyte in solid state Lithium batteries
Dental filling materials
Recreational products – skating shoe, base ball shafts, bicycle frames
Space shuttle
Disadvantages of composite materials
• High cost of raw materials and fabrication
• Composites are brittle and thus are more easily damageable
• Transverse properties may be weak
• Matrix is weak, therefore, low toughness
• Reuse and disposal may be difficult
• Health hazards during manufacturing and after use
• Joining to parts is difficult
• Repair introduces new problems, for the following reasons:
• • Materials require refrigerated transport and storage and have limited shelf life
• • Hot curing is necessary in many cases requiring special tooling
• • Curing takes time
• Analysis is difficult
• Matrix is subject to environmental degradation
Applications of composites in electronics and electrical industries
1. A PCB substrate must have good dielectric performance ie, it must insulate the conductive
layers from one another by blocking electrical conductivity, to minimize electrical signal loss,
crosstalk between conductive layers and noise
The majority of PCBs are made with E-glass/epoxy
Resin alternatives include vinyl ester and polyester, for commodity boards, and cyanate ester,
polyimide and bismaleimide triazine (BT) for more demanding, elevated-temperature
applications
2. Electromagnetic shielding
The effect of electromagnetic shielding is
to reduce the electromagnetic field effect
in a certain area generated by some
radiation sources, and to effectively control
the harm caused by electromagnetic radiation
from one area to another
Coating fillers with magnetic materials or incorporation of magnetic mat. in the polymer matrix
Carbon – carbon composites have good shield effectiveness
3. Risk from electromagnetic radiation
If human beings are exposed to the EM waves, the network of veins in high risk organs such as
eyes might be affected due to heat build-up in the eyes by the EM waves which could not be
easily dissipated
To avoid these hazards to human beings and to protect the sensitive circuits EMI shielding is
essential
The use of low-resistance conductor material has a reflection and guiding effect on
electromagnetic energy flow and within the conductor material
It create the current and magnetic polarization which is opposite with the source of
electromagnetic field, thereby reduce the effect of radiation source in electromagnetic field, by
shielding effectiveness
4. Conductive mechanism of composite conductive polymer
With the increase of the concn. of conductive filler, the conductivity of the polymer increases
slowly
When the concentration reaches a certain value, the conductivity increases sharply, the polymer
becomes a conductor, and the filler concentration continues to increase but conductivity has not
changed much
The conductivity filler concentration at which the conductivity changed abruptly is called the
'diafiltration threshold’
when the content of the conductive filler reaches the 'diafiltration threshold', the conductive
particles contact each other to form an infinite network
The formation of conductive channels, carriers can freely move within the system thereby
making the composite conductive
5. Electrical switching and insulation
Properties that composite materials have include : • Dielectric strength • High thermal
conductivity • Low electrical conductivity for insulation • Electromagnetic shielding effectiveness
• Heat resistance • Low coefficient of thermal expansion
• Durability to withstand repeated use without a decrease in performance
• Moisture resistance for safety and durability • Sound baffling for quieter operation
Examples

Paper – phenolic sheet Glass- melamine sheet Cotton – epoxy tube Glass – polyimide sheet

a. Paper-Phenolic materials
Norplex-Micarta offers a variety of paper phenolic sheets. This cost-effective line of products
consists of multiple plies of various papers impregnated with phenolic resins and laminated
under heat and pressure to produce a thermoset composite. Both papers and resins can be
modified to change the finished properties of the final laminate. These products offer thermal,
mechanical isolation, and thermal and electrical insulation properties
b. Epoxy Cotton/Linen Tube
A tube made from a fine cotton fabric and an epoxy resin system. It has low moisture absorption
and excellent dimensional stability and chemical resistance
c. Paper-Epoxy Materials
These products consist of multiple plies of various papers impregnated with specialty epoxy resin
systems and laminated under heat and pressure to produce a thermoset composite. Both papers
and resins can be modified to change the finished properties of the final product, and once
cured, they will not melt like most thermoplastics. Thermoset epoxy composites are ideal for
applications ranging from small switch parts to insulating high voltage tap chargers in power
transformers, and other applications requiring electrical insulation properties
d. Glass/polyimide
It consists of woven glass fabric with polyimide resin. The product is engineered to maintain
excellent physical properties at 240°C, making it suitable for high temperature applications. It
offers a low coefficient of thermal expansion, as well as high mechanical strength and consistent
quality. It can be used for structural components, thermal insulators, PCB manufacture and
assembly, and high temperature gaskets in petrochemical plants and other applications requiring
excellent compressive strength, low moisture absorption, and excellent chemical resistance
6. Phenolic-matrix and melamine composites are used in many electronics including printed
circuit boards, gears, and insulators
Insulation, circuit boards, and components requiring a high resistance to heat will often be made
from a silicone-based composite
Additional applications include
• Control system components • Circuit breakers • Arc chutes • Arc shields
• Terminal blocks and boards
• Substation equipment
• Microwave antennas
• Standoff insulators
• Pole line hardware
• Printed wiring boards • Switchgear • Panel boards
• Server rooms • Metering devices
• Lighting components
7. Wearable electronics – worn by a person for memory communication and senses
Ex : smart watches/chips
• Graphene/CNT polymer composites are widely being used to make wearable electronics
• Silver nanofillers in elastomer composite used in wearables
8. Electronic sensors
Carbon black polymer odour and flavour sensors for detecting vapours
Used for environmental monitoring to check air quality,
crime prevention such as bomb detection, quality control
Reinforcing phase: Dispersed carbon black particles
Reinforcing medium : Polystyrene
9. Batteries – Li ion battery
10. Satellite electronics mounted on composite panel
11. Lightning harvester
Graphene based composite technology is used to manufacture ultra-long cables - of circa 8 miles
in length
These ultra-long cables would have a highly-conductive coating of graphene - effectively making
them lightning rods which can reach up into the clouds
Clouds contain a massive amount of energy, in the form of static electricity, or the difference in
voltage between the bottom of a cloud and the ground
Lightning occurs when this voltage difference builds up to such an extent that electricity leaps
across this gap
The highly-conductive graphene coating on a GC (ground check cable ) composite cable (held
aloft by weather balloons) is used to harness electricity from clouds
As Electricity flows - even the extremely large bursts from lightning strikes - would travel down
the graphene-coated cable into a super-capacitor array, which could then release electricity into
the power grid in a controlled way