Understanding Composite

Materials
Composite materials represent one of engineering's most
versatile innovations. They combine two or more distinct
materials to create something extraordinary.

Let's explore these remarkable materials that power everything from

ancient buildings to spacecraft.
What is a Composite?
Definition Key Concept
A material made from two or more Composites leverage synergy. The
constituent materials with significantly combined material outperforms its
different physical or chemical properties. individual components.
This allows engineers to design materials
When combined, they produce a material
with precise property profiles for specific
with characteristics different from the
applications.
individual components.
Example 1: Concrete
Cement Binder
Provides adhesive capacity and fills spaces between aggregate particles.

Aggregate
Rock and sand provide compressive strength and volume stability.

Applications
Used in foundations, buildings, bridges, and dams worldwide.
Example 2: Fiberglass
Glass Fibers Polymer Matrix
Thin strands of glass provide Surrounds and protects
strength and stiffness to the fibers while transferring
composite. loads between them.

Common Uses
Boat hulls, car bodies, bathtubs, and swimming pools benefit from
fiberglass.
Example 3: Carbon Fiber Reinforced
Reinforced Polymer
Structure Properties
Thin carbon fibers (5-10 μm Extremely high strength-to-weight
diameter) embedded in polymer ratio, exceeding most metals.
matrix like epoxy.
Excellent fatigue resistance and
Fibers can be woven into fabrics or low thermal expansion.
aligned in specific directions.

Applications
Aircraft components, high-end sports equipment, race cars, and bicycle
frames.

Increasingly used in consumer electronics and medical devices.

Example 4: Wood
Natural Origin
Evolved over millions of years as an efficient structural
material for trees.

2 Microstructure
Cellulose fibers (20-50% by weight) embedded in lignin matrix.

Human Use
One of humanity's oldest building materials, still widely used
today.
General Physical Properties of Composites

High Strength-to-Weight Improved Stiffness Fatigue Resistance Directional Properties

Resist deformation under Withstand repeated loading Customizable strength in
Exceptional performance applied forces. cycles. specific directions.
with minimal mass.
Physical Properties: Example –
CFRP ( carbon fiber reinforced
polymer)
3,500 MPa 1.55 g/cm³
Tensile Strength Density
Exceeds many steels while weighing Less than one-fifth the density of
significantly less. steel.

5x
Specific Strength
Strength-to-weight ratio compared to
steel.
Physical Properties: Example -
Fiberglass
Property Value Comparison

Tensile Strength 1,500-2,000 MPa Higher than

aluminum

Density 1.5-2.0 g/cm³ 30-40% of steel

Electrical 0 S/m Perfect insulator

Conductivity

Thermal Expansion 10-20 ppm/°C Similar to aluminum

General Chemical Properties of Composites
Corrosion Resistance
Resist degradation from environmental exposure.

Chemical Stability
2
Maintain properties when exposed to chemicals.

Thermal Properties
Customizable thermal expansion and conductivity.
Chemical Properties: Example -
Kevlar
Chemical Resistance
Highly resistant to many acids and bases.

Minimal degradation in harsh environments.

Thermal Stability
Maintains integrity at temperatures up to 500°C.

Used in high-temperature applications.

Thermal Expansion
Very low thermal expansion coefficient.

Maintains dimensional stability during temperature changes.

Chemical Properties: Example - CMCs

Temperature Resistance Oxidation Resistance

Withstand temperatures exceeding Resist chemical breakdown in high-
1000°C without degradation. temperature oxygen environments.

Mechanical Stability Thermal Insulation

Maintain strength and toughness at Low thermal conductivity provides
elevated temperatures. excellent heat shielding properties.
Classification of Composites: Overview
Matrix Material
1
The continuous phase that surrounds and supports reinforcement.

Reinforcement Type
The form and function of the strengthening components.

Reinforcement Structure
The arrangement and orientation of reinforcing elements.
Classification by Matrix Material
Metal Matrix (MMCs)
Use metals like aluminum or titanium as
the continuous phase.
Polymer Matrix (PMCs)
Examples: aluminum-silicon carbide,
Use thermoplastic or thermoset polymers titanium-boron fiber.
as the continuous phase.
Ceramic Matrix (CMCs)
Examples: fiberglass, carbon fiber
composites. Use ceramic materials as the continuous
phase.

Examples: silicon carbide reinforced silicon

carbide.
Polymer Matrix Composites (PMCs)

Glass Fiber Reinforced Polymer (GFRP) exemplifies PMCs. It combines glass fibers with polyester or epoxy resins. This creates
strong, lightweight, corrosion-resistant structures.
Metal Matrix Composites (MMCs)

Microstructure Brake Applications Aerospace Use

Silicon carbide particles (10-20%) MMCs offer superior heat dissipation and Light weight and high stiffness make
dispersed throughout aluminum matrix wear resistance in high-performance MMCs ideal for critical aerospace
provide reinforcement. braking systems. structures.
Ceramic Matrix Composites (CMCs)
Classification by Reinforcement
Type
Particle-Reinforced Fiber-Reinforced
Discrete particles dispersed in Continuous or chopped fibers
matrix material. embedded in matrix.

Examples: concrete, metal Examples: carbon fiber,

matrix composites with ceramic fiberglass, aramid fiber
particles. composites.

Structural Composites
Combinations of materials in specific geometrical arrangements.

Examples: sandwich panels, laminates, honeycomb structures.

Particle-Reinforced Composites

70% 30 MPa 4.5 GPa

Aggregate Content Compressive Strength Young's Modulus
Typical percentage of sand and gravel in Average strength of structural concrete. Measure of concrete's stiffness under load.
concrete mixture.

Concrete exemplifies particle reinforcement at scale. Combining cement with sand and gravel creates a versatile construction material.
Particle size, distribution, and volume fraction dramatically affect properties.
Fiber-Reinforced Composites
Superior Strength
Carbon fibers provide exceptional tensile strength (3,500-7,000 MPa).

Lightweight Design
CFRP can reduce component weight by 40-70% versus metals.

Directional Properties
Fiber orientation creates customizable mechanical properties.

Fatigue Resistance
Carbon fiber composites show minimal degradation under cyclic
loading.
Structural Composites
Honeycomb Structure Applications

Two thin, stiff face sheets separated by lightweight honeycomb Aircraft floor panels must support heavy loads while remaining
core. lightweight.

This arrangement maximizes bending stiffness while Spacecraft structures require exceptional stiffness-to-weight
minimizing weight. ratios.

The honeycomb core provides shear strength and stabilizes Sporting goods like skis and snowboards use similar principles.
face sheets.
Classification by Fiber Structure
Continuous Fiber
Unbroken fibers running through the entire component.

Highest strength in fiber direction.

Discontinuous Fiber
Short fiber segments randomly or partially oriented.

More isotropic properties, easier processing.

Hybrid Composites
Multiple fiber types combined in single matrix.

Optimizes cost/performance balance.

Continuous Fiber Composites

Unidirectional Woven Multi-directional

All fibers aligned in Fibers interlaced in Layers with different
same direction. perpendicular fiber orientations.
Maximum strength directions. Balanced Customizable strength
along fiber axis. properties. profile.

Unidirectional carbon fiber prepreg exemplifies continuous reinforcement.

Aircraft structures leverage this precise fiber alignment for maximum
strength in critical directions.
Discontinuous Fiber Composites
Hybrid Composites
Carbon/Aramid Hybrid Performance Advantage Design Flexibility
Carbon provides stiffness and Delivers superior ballistic Engineers can optimize layer
strength. Aramid contributes protection while maintaining sequence and fiber ratio. This
impact resistance and vibration structural integrity. Used in aircraft creates customized performance
damping. and military applications. profiles.
Composite Manufacturing Processes: Overview
Open Molding
Hand lay-up and spray-up techniques.

Closed Molding
RTM and compression molding processes.

Filament Winding
Fiber placement around rotating mandrel.

Pultrusion
Continuous production of constant cross-sections.
Open Molding: Hand Lay-up
Mold Preparation
Apply release agent to prevent composite from sticking to mold.

Reinforcement Placement
Position fiber mats or fabrics into mold by hand.

Resin Application
Apply liquid resin using brushes or rollers.

Air Removal
Use rollers to remove trapped air bubbles.

Curing
Allow resin to cure at room temperature or with mild heat.
Open Molding: Spray-up
Spray Application
Special gun chops continuous fiber rovings into short lengths.

Simultaneously sprays fibers and catalyzed resin onto mold surface.

Consolidation
Workers use rollers to compact material and remove air bubbles.

This ensures proper fiber wet-out and material distribution.

Curing & Finishing

Composite cures at room temperature or with mild heat.

Edges are trimmed and surface is finished as needed.

Closed Molding: Resin Transfer Molding
Mold Closure
Preform Preparation Preform placed in mold tool which is
Dry fiber reinforcement shaped to then closed and sealed.
match final part geometry.
Resin Injection
Catalyzed resin pumped into mold
cavity under pressure.
Demolding
Finished part removed from mold after Curing
complete cure. Resin cures through chemical reaction,
often accelerated by heat.
Closed Molding: Compression Molding
Process Steps Advantages

1. Preform preparation from sheet molding compound (SMC) • Very high production rates (1-5 minutes per cycle)

• Excellent part reproducibility

2. Placement in heated mold cavity • Good surface finish
3. Application of heat (140-160°C) and pressure (500-1500 psi) • Minimal material waste

• Cost-effective for high volumes

4. Curing for 1-3 minutes

5. Demolding of finished part

Filament Winding

Process Products Technology

Continuous fibers impregnated with Creates cylindrical or spherical pressure Computer-controlled winding patterns
resin are wound onto a rotating mandrel vessels, pipes, and tanks with exceptional optimize fiber orientation for specific
in precise patterns. hoop strength. load requirements.
Pultrusion
Fiber Unwinding
Continuous reinforcement from creels.

Resin Impregnation
Fibers pass through resin bath.

Preforming
Guide shapes material into final configuration.

Heated Die
Curing as material is pulled through.

Cutting
Continuous profile cut to desired length.
Emerging Technologies: Additive
Manufacturing
Continuous Fiber 3D Printing Process Innovation
Recent technology embeds Specialized print heads deposit fiber
continuous carbon or glass fibers and polymer simultaneously.
within thermoplastic filament.
Software optimizes fiber placement
Creates parts with exceptional for maximum structural
strength-to-weight ratio. performance.

Medical Applications
Custom orthopedic implants match patient anatomy precisely.

Fiber reinforcement provides necessary strength for load-bearing applications.

Future Trends in Composite Materials
Nanocomposites Self-Healing Multifunctional
Composites Composites
Incorporate nanoscale
reinforcements like Contain Combine structural
carbon nanotubes or microencapsulated properties with
graphene. These healing agents that additional
provide extraordinary release upon damage. functionalities. These
property improvements This autonomously include energy storage,
at minimal weight repairs cracks and sensing, and actuation
addition. extends component capabilities.
lifespan.

Sustainable
Composites
Utilize bio-based resins
and natural fibers.
These reduce
environmental impact
while maintaining
performance.
Conclusion: The Future of Composites

Composite materials will continue revolutionizing industries through increasingly sophisticated design approaches. Advanced
manufacturing, sustainability improvements, and multifunctional capabilities will drive innovation across aerospace, energy,
construction, and healthcare sectors.