Chapter - Five

Composite Materials
 Introduction to Composite Materials
2
 Main Contents
3

▪ Identify the four main divisions of composite materials.

▪ Understand the difference in strengthening mechanism for large-particle
and dispersion-strengthened particle-reinforced composites.
▪ Distinguish the three different types of fiber reinforced composites on
the basis of fiber length and orientation.
▪ Calculate longitudinal modulus and longitudinal strength for an aligned
and continuous fiber reinforced composite.
▪ Compute longitudinal strengths for discontinuous and aligned fibrous
composite materials.
▪ State the three common fiber reinforcements used in polymer-matrix
composites and explain the desirable characteristics and limitations.
▪ State the desirable features of metal–matrix composites.
▪ Note the primary reason for the creation of ceramic-matrix composites.
▪ State and briefly describe the two sub classifications of structural
composites.
 What is a composite?
4

 What are composite materials?

 How are they manufactured?
 What advantages and drawbacks do composites have over metals?
 What are typical applications of this materials?

 Composite is a material that deliberately designed, engineered

and manufactured from multiphase materials to get combinations
of special properties of the constituent materials.
 Examples:
 Pearlitic steels – composed of a-ferrite and cementite
 Concrete reinforced with steel

 Epoxy reinforced with graphite fibers and so on.

 What is a composite?
5

 A composite is a multiphase material that is artificially made.

 According to this principle of combined action, better

property combinations are fashioned by the judicious

combination of two or more distinct materials.

 Property trade-offs are also made for many composites.

 Most composites have been created to improve combinations

of mechanical characteristics such as stiffness, toughness,
weight-to-strength ratio, and high-temperature strength.
 Importance of Composites
6

 High strength

 Light weight Composite phases

 Design flexibility

 Consolidation of parts Matrix Dispersed

 Net-shape manufacturing The reinforcement

The main or larger
 Dimensional stability component of the or smaller
composite material. component of the
 High fatigue life composite material.

 Better corrosion resistivity

 Properties of Composites: depend on dispersed phases
7

 Composites: geometrical and spatial characteristics

of particles of the dispersed phase;

Composites: (a) concentration, (b) size, (c) shape, (d) distribution, and (e) orientation.
 Classification of Composites
8

 Four main divisions of composites: in terms of the

phase condition
 Particle Reinforced composites
9

• Examples:
 Cont….d
10

▪ Large-particle composites are used with all three material

types (metals, polymers, and ceramics).
▪ The cermets are examples of ceramic–metal composites.
▪ The most common cermet is cemented carbide.
▪ These composites are used extensively as cutting tools for
hardened steels.
▪ Toughness is enhanced by their inclusion in the ductile metal
matrix.
▪ No single material could possibly provide the combination of
properties possessed by a cermet.
 Cont….d
11

• Elastic modulus, Ec, of composites:

- two approaches.

Upper bound

Lower bound

E and V denote the elastic modulus and volume

fraction, respectively, and the subscripts c, m, and p
represent composite, matrix, and particulate phases,
respectively. Adapted from Fig. 16.3, Callister 9e,
 Fiber Reinforced Composites
12

Aligned Continuous fibers

• Examples:
- Metal: g'(Ni3Al)-a(Mo) - Glass w/SiC fibers
by eutectic solidification. formed by glass slurry
Eglass = 76GPa; ESiC = 400GPa.

(a)

(b)

From W. Funk and E. Blank, “Creep deformation

of Ni3Al-Mo in-situ composites", Metall. Trans. A
Vol. 19(4), pp. 987-998, 1988. Used with
permission.
 Cont….d
13

Discontinuous, random 2D fibers C fibers:

very stiff
• Example: Carbon-Carbon very strong
- process: fiber/pitch, then C matrix:
burn out at up to 2500C. less stiff
- uses: disk brakes, gas (b) view onto plane less strong
turbine exhaust flaps, nose fibers lie
cones. in plane

(a)

• Other variations: Adapted from F.L. Matthews and R.L. Rawlings,

Composite Materials; Engineering and Science,
- discontinuous, random 3D Reprint ed., CRC Press, Boca Raton, FL, 2000. (a) Fig.
4.24(a), p. 151; (b) Fig. 4.24(b) p. 151. (Courtesy I.J.
- discontinuous, 1D Davies) Reproduced with permission of CRC Press,
Boca Raton, FL.
 Cont…d
Influence of Fiber Length
14

• Critical fiber length for effective stiffening & strengthening:

fiber strength in tension fiber diameter

f d
fiber length  15 shear strength of
c fiber-matrix interface

l >15lc
lc = critical length

Ex: For fiberglass, fiber length > 15mm needed

Why? Longer fibers carry stress more efficiently!
 Cont…d
Influence of Fiber Length
15

Shorter, thicker fiber: Longer, thinner fiber:

 d f d
fiber length  15 f fiber length  15
c c

7
Poorer fiber efficiency Better fiber efficiency
 Cont…d
Influence of Fiber Length
16

The fiber length l (a) is equal to the critical length lc, (b) is
greater than the critical length, and (c) is less than the critical
length for a fiber-reinforced composite that is subjected to a
tensile stress equal to the fiber tensile strength s*f.
 Cont…d
Influence of Fiber Orientation & Concentration
17

• Estimate of Ec and TS:

 d
- valid when fiber length  15 f
c
- Elastic modulus in fiber direction:
Ec = Em Vm + KE f Vf
efficiency factor:
- aligned 1D: K = 1 (anisotropic)
- random 2D: K = 3/8 (2D isotropy)
- random 3D: K = 1/5 (3D isotropy)

- TS in fiber direction:
(TS)c = (TS)m Vm + (TS) f Vf (aligned 1D)
 Cont…d
Influence of Fiber Orientation & Concentration
18

Schematic representations of (a) continuous and aligned, (b) discontinuous and

aligned, and (c) discontinuous and randomly oriented fiber–reinforced composites.

• These three fiber-orientations are very important considerations in fiber composite

materials design.
 Cont…d
Influence of Fiber Orientation & Concentration
19

▪ A fiber-reinforced composite consisting of these fiber and

matrix materials exhibits the uniaxial stress–strain response.

(a) for brittle

fiber and
ductile matrix
materials.
(b) for an
aligned fiber–
reinforced
composite.
 Cont…d
Mechanical Properties of Composites
20

▪ Mechanical responses of composite materials are depend on;

o the stress–strain behaviors of fiber and matrix phases,
o the phase volume fractions, and
o the direction in which the stress or load

• In the continuous and aligned fiber-reinforced composite:

o Direction of loading is very determining factor – when in;
- Longitudinal loading: Ecl = EmVm + EfVf
- Transversal loading:
• These mechanical properties are basic parameters in its design.
 Exercise: on continuous & aligned fibers
21

Property Determinations for a Glass Fiber–Reinforced

Composite — Longitudinal Direction
➢ A continuous and aligned glass fiber–reinforced composite consists of
40 vol% glass fibers having a modulus of elasticity of 69 GPa and
60 vol% polyester resin that, when hardened, displays a modulus of
3.4 GPa. [refer to your textbook (Callister 9th ed.)]
 Fiber orientation - reinforcement efficiency
22

Reinforcement Efficiency of Fiber Reinforced Composites for

Several Fiber Orientations and at Various Directions of Stress
Application.
 Structural Composites
23

▪ A structural composite is a multi-layered and normally low-

density composite used in applications requiring structural
integrity, ordinarily high tensile, compressive, and torsional
strengths and stiffnesses.
▪ The properties of these composites depend not only on the
properties of the constituent materials, but also on the
geometrical design of the structural elements.
▪ Laminar composites and sandwich panels are two of the most
common structural composites.
 Structural Composites
24

▪ A laminar composite is composed of two-dimensional sheets or

panels (plies or laminae) bonded to one another.

Figure 16.16 Lay-ups (schematics) for laminar composites. (a)

Undirectional; (b) cross-ply; (c) angle-ply; and (d) multidirectional.
 Structural Composites
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• Stacked and bonded fiber-reinforced sheets

- stacking sequence
- benefit: balanced, in-plane stiffness

• Sandwich panels
- low density, honeycomb core
- benefit: small weight, large bending stiffness
 Structural Composites
26

Sandwich panels: are a class of structural composites, are designed to

be lightweight beams or panels having relatively high stiffnesses and
strengths.
▪ A sandwich panel consists of two outer sheets, faces, or skins that are
separated by and adhesively bonded to a thicker core.
▪ Sandwich panels are used in a wide variety aircraft, construction,
automotive, and marine applications.

Figure: the cross section

of a sandwich panel.
 Structural Composites
27

▪ Sandwich panel is a cost-effective composite because core materials

are less expensive than materials used for the faces.
▪ Core materials typically fall within three categories: rigid polymeric
foams, wood, and honeycombs.
Nano-Composites
▪ The material’s world is experiencing a revolution with the development
of a new class composite materials — the nanocomposites.
▪ Nanocomposites are composed of nano-sized particles (nanoparticles)
that are embedded in a matrix material.
▪ These nanocomposite materials have carved out niches in a host of
different technologies and industries, including the following:
o Gas-barrier coatings o Mechanical strength enhancement
o Energy storage o Electrostatic dissipation
o Flame-barrier coatings
o Dental restorations
 Types of Composite Materials: based Matrix
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1) Polymer Matrix Composites (PMCs): when the main

body or component is polymer.

2) Metal Matrix Composites (MMCs): when the main

body or component is metal.

3) Ceramic Matrix Composites (CMCs): when the main

body or component is ceramic.
 Polymer Matrix Composites (PMCs):
30

▪ PMCs: some of the composites under this class are;

a) glass fiber–reinforced polymer (GFRP) composites

b) carbon fiber–reinforced polymer (CFRP) composites

c) aramid fiber–reinforced polymer composites; - aramid fibers are

high-strength, high-modulus materials

d) other fiber reinforcement materials – such as boron, silicon

carbide, and aluminum oxide.

▪ Glass, carbon, and the aramids are the most common fiber

reinforcements incorporated into polymer matrices.

 Polymer Matrix Composites (PMCs)
31

 Carbon fiber–reinforced polymer (CFRP) composites: Carbon is a high-

performance fiber material that is the most commonly used
reinforcement in advanced (i.e., non-fiberglass) polymer-matrix
composites. The reasons for this are as follows;
1) Carbon fibers have high specific moduli and specific strengths.
2) They retain their high tensile modulus and high strength at elevated
temperatures.
3) Carbon fibers are not affected by moisture or a wide variety of
solvents, acids, and bases – at room temperature.
4) These fibers exhibit a diversity of physical and mechanical
characteristics, allowing composites incorporating these fibers to have
specific engineered properties.
5) Fiber- and composite-manufacturing processes have been developed
that are relatively inexpensive and cost effective.
 Polymer Matrix Composites (PMCs)
32

▪ Properties of continuous and aligned glass, carbon, and aramid

fiber reinforced epoxy – matrix composites in longitudinal and
transverse directions.
 Polymer Matrix
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 Thermosets  Thermoplastics

▪ Polyester ▪ Polypropylene

▪ Epoxy ▪ polyvinyl chloride

▪ Polyamide ▪ Nylon
 Fiber Reinforced Polymer Matrix
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▪ Matrix
• Transfer Load to Reinforcement
• Temperature Resistance
• Chemical Resistance
▪ Reinforcement
• Tensile Properties
• Stiffness
• Impact Resistance
 Polymer Matrix Types
35

Polyester
 Polyesters have good mechanical properties, electrical properties and
chemical resistance. Polyesters are amenable to multiple fabrication
techniques and are low cost.
Vinyl Esters
 Vinyl Esters are similar to polyester in performance. Vinyl esters have
increased resistance to corrosive environments as well as a high
degree of moisture resistance.
Epoxy
 Epoxies have improved strength and stiffness properties over
polyesters. Epoxies offer excellent corrosion resistance and resistance
to solvents and alkalis.
 Flexibility and improved performance is also achieved by the
utilization of additives and fillers.
 Reinforcement
36

 Fibers can be:

⚫ Natural fiber, and

⚫ Synthetic fiber

 Fiber Type  Textile Structure

⚫ Fiberglass ⚫ Unidirectional

⚫ Carbon ⚫ Woven

⚫ Aramid ⚫ Braid
Fiber Factors

 The fiber factors that contribute to the

mechanical performance of a composite:
▪ Length
▪ Orientation
▪ Shape
▪ Material
 Fiber Factor - Length
 Long Fibers
▪ Easy to orient
▪ Easy to process
▪ Higher impact resistance
▪ Dimensional stability
 Short Fibers
▪ Low Cost
▪ Fast cycle time
Synthetic-fibers
Fiber Factor - Orientation

 One direction orientation

▪ High stiffness and strength in that direction.
▪ Low stiffness and strength in other directions.

 Multi-direction orientation
▪ Less stiffness but more direction independent.
Fiber Factor - Shape

 Most common shape is circular.

 Hexagon and square shapes give high

packing factors.

Fiber Factor - Material

 Graphite/carbon and aramids have high
strength and stiffness.
 Glass has low stiffness but cost less.
 Matrix Factors

 The matrix factors which contribute to the

mechanical performance of composites are:
▪ Bind fibers together
▪ Protect fibers from environment
▪ Shielding from damage due to handling
▪ Distributing the load to fibers.

Factors other than Fiber and Matrix-Fiber-matrix

interface.
 Fiberglass
42

 E-glass: Alumina-calcium-borosilicate glass

(electrical applications)
S-2 glass: Magnesium alumino-silicate glass
(reinforcements)
▪ Glass offers good mechanical, electrical, and
thermal properties at a relatively low cost.

Fiber-glass
 Carbon Fiber
43

 PAN: Fiber made from Polyacrylonitrile

precursor fiber

 High strength and stiffness

 Large variety of fiber types available

Carbon Fiber
 Aramid (Polyparaphenylene terephathalamide)
44

 Kevlar™ and Twaron™

• Kevlar (para-aramid) is a heat-resistant and strong

synthetic fiber, related to other aramids such as Nomex
and Technora.
 Para aramid fiber characterized by Para-aramid filament yarn

high tensile strength and modulus

 Excellent Impact Resistance
 Good Temperature Resistance

Kevlar
Carbon vs Aramid vs Fiberglass vs Kevlar Comparisons
45

 Weight considerations: aramids (heat resistant synthetic fibers) are

the lightest < carbon < fiberglass.

 Strength considerations: carbon is the strongest > fiberglass >

aramids.

 Impact resistance: Kevlar(man-made fiber) is the toughest >

fiberglass > carbon.

 Stiffness considerations: carbon is the stiffest > aramids >

fiberglass.

 Cost considerations: fiberglass is cost effective > aramids > carbon.

 Metal Matrix Composites (MMCs)
46

▪ For MMCs the matrix is a ductile metal.

▪ The reinforcement in MMCs may improve:
o specific stiffness,
o specific strength,
o abrasion resistance,
o creep resistance,
o thermal conductivity, and dimensional stability.
▪ The advantages of MMCs over PMCs includes: higher operating
temperatures, non-flammability, and greater resistance to
degradation by organic fluids.
▪ MMCs are more expensive than PMCs.
 Metal Matrix Composites (MMCs)
47

▪ In MMCs; super-alloys, and alloys of Al, Mg, Ti, and Cu are used
as matrix materials.
▪ The reinforcement may be in the form of particulates.
▪ Processing of MMCs involves at least two steps:
o consolidation or synthesis, followed by
o shaping operation – may be by forging, extrusion, rolling.
▪ Automobile manufacturers have recently begun to use MMCs in
their products.
• An aluminum alloy matrix that is reinforced with aluminum oxide
and carbon fibers. This resists wear and thermal distortion.
 Metal Matrix Composites (MMCs)
48

• Metal-matrix composites are also employed in drives-hafts,

extruded stabilizer bars, and forged suspension and
transmission components.
▪ The aerospace industry also employs MMCs in the form of
advanced aluminum alloy metal-matrix composites.
• Global Positioning System (GPS) satellites use silicon carbide-
aluminum and graphite–aluminum MMCs for electronic
packaging and thermal management systems.
 Metal Matrix Composites (MMCs)
49

▪ Properties of several metal-matrix composites reinforced with

continuous and aligned fibers. MMC - increased creep resistance.

• Some matrix–reinforcement combinations are highly reactive at

elevated temperatures.
 Metal Matrix
50

 Aluminum
 Titanium
 Copper

▪ For metal-matrix composites (MMCs) the matrix is a ductile metal.

▪ The reinforcement may improve specific stiffness, specific strength,
abrasion resistance, creep resistance, thermal conductivity, and
dimensional stability.
▪ Metal-matrix composites are much more expensive than PMCs,
and, therefore, MMC use is somewhat restricted.
 Ceramic Matrix Composites (CMCs)
51

▪ CMCs: ceramic-matrix composites may be fabricated

using hot pressing, hot isostatic pressing, and liquid-
phase sintering techniques.

▪ CMCs: increased toughness

▪ The fracture toughnesses of

ceramics have been improved
significantly by the development
of a new generation of CMCs.
 Ceramic Matrix Composites (CMCs)
52

 Typically; CaO, MgO, Y2O3, and CeO are used as stabilizers.

Figure: transformation toughening. (a) A crack prior to inducement of the ZrO2 particle
phase transformation. (b) Crack arrestment due to the stress-induced phase transformation.
 Ceramic Matrix
53

 Carbon

 Silicon carbide

 Calcium AluminoSilicate

 Lithium AluminoSilicate
 Composites vs. Metals, Ceramics
54

 Comparison based on six primary material selection

parameters
 Specific Strength vs. Year
55

10
Aramid Fibers,
Carbon Fibers
Specific Strength, (10 6) in

6
Composites
4

2
Wood,
Bronze Cast Iron Steel
stone Aluminum
0
1400 1500 1600 1700 1800 1900 2000
Year
 Drawbacks of Composites
56

 High cost of fabrication of composites

 Complex mechanical characterization

 Complicated repair of composite structures

 High combination of all required properties may not

be available
 Processing techniques
57

▪ Pultrusion is used for the manufacture of components having

continuous lengths and a constant cross-sectional shape (rods,
tubes, beams, etc.).
▪ A pulling device draws the stock through the dies and also
determines the production speed.
 Applications of Composites
 From virtual to real is the track that aircraft
follow. Here, the Boeing 787 Dreamliner
takes shape. Its fuselage, made of
composites, consists of four cylindrical
sections.

 Composites, because of their light weight

and strength, are gaining favor as a
material for aircraft. According to Boeing,
Boeing Aircraft
composite materials constitute about 50
percent of the aircraft by weight.
 Applications of Composites
▪ Rocket structures
▪ Aircraft structures
▪ Wind turbine
▪ Automobile body
▪ Medical equipment
▪ Marin industry
▪ Electronic components
 Applications of Composites
60

Composites – B2 Stealth Bomber

Composites – B2 Stealth Bomber

Courtesy : Gary Eisenberg; Antelope Valley Community College; Lancaster , CA

 Summary
61

• Composites are classified according to:

- the matrix material (CMC, MMC, PMC)
- the reinforcement geometry (particles, fibers, layers).
• Composites enhance matrix properties:
- MMC: enhance sy, TS, creep performance
- CMC: enhance Kc (Fracture toughness)
- PMC: enhance E, sy, TS, creep performance
• Particulate-reinforced:
- Elastic modulus can be estimated.
- Properties are isotropic.
• Fiber-reinforced:
- Elastic modulus and TS can be estimated along fiber dir.
- Properties can be isotropic or anisotropic.
• Structural composite:
- Based on build-up of sandwiches in layered form.
62

End of the chapter!

Thank you!!