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    ME 257 Composite Materials

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    This document provides an overview of composite materials for a class called ME 257 Composite Materials taught by Professor James C Iatridis in spring 2006. It defines composite materials as consisting of two or more constituents including a reinforcement phase (e.g. fibers) and a binder phase (e.g. matrix). It discusses the advantages of composites, various applications, types of composites based on the matrix and reinforcement phases, forms of reinforcement, matrix materials, manufacturing methods, and material forms.

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    ME 257 Composite Materials

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    arun_premnath
    375 views30 pages
    This document provides an overview of composite materials for a class called ME 257 Composite Materials taught by Professor James C Iatridis in spring 2006. It defines composite materials as consisting of two or more constituents including a reinforcement phase (e.g. fibers) and a binder phase (e.g. matrix). It discusses the advantages of composites, various applications, types of composites based on the matrix and reinforcement phases, forms of reinforcement, matrix materials, manufacturing methods, and material forms.

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    This document provides an overview of composite materials for a class called ME 257 Composite Materials taught by Professor James C Iatridis in spring 2006. It defines composite materials as consisting of two or more constituents including a reinforcement phase (e.g. fibers) and a binder phase (e.g. matrix). It discusses the advantages of composites, various applications, types of composites based on the matrix and reinforcement phases, forms of reinforcement, matrix materials, manufacturing methods, and material forms.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    375 views30 pages

    ME 257 Composite Materials

    Uploaded by

    arun_premnath
    This document provides an overview of composite materials for a class called ME 257 Composite Materials taught by Professor James C Iatridis in spring 2006. It defines composite materials as consisting of two or more constituents including a reinforcement phase (e.g. fibers) and a binder phase (e.g. matrix). It discusses the advantages of composites, various applications, types of composites based on the matrix and reinforcement phases, forms of reinforcement, matrix materials, manufacturing methods, and material forms.

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    ME 257 Composite Materials

    Prof. James C Iatridis


    Spring 2006
    Terril 222 – 12:20-1:10pm
    Composite materials –
    Introduction
    Definition: a material composed of 2 or
    more constituents
     Reinforcement phase (e.g., Fibers)
     Binder phase (e.g., compliant matrix)

    Advantages
     High strength and stiffness
     Low weight ratio
     Material can be designed in addition to the
    structure
     Can manufacture structures and eliminate
    joints
    Applications
     Straw in clay construction by
    Egyptians
     Aerospace industry
     Sporting goods
     Automotive
     Construction
    Types of Composites
    Matrix Metal Ceramic Polymer
    phase/Reinforc
    ement Phase
    Metal Powder metallurgy Cermets (ceramic- Brake pads
    parts – combining metal composite)
    immiscible metals

    Ceramic Cermets, TiC, TiCN SiC reinforced Fiberglass


    Cemented carbides – Al2O3
    used in tools
    Fiber-reinforced
    Tool materials
    metals

    Polymer Kevlar fibers in an


    epoxy matrix

    Elemental Fiber reinforced Rubber with


    (Carbon, metals carbon (tires)
    Auto parts Boron, Carbon
    Boron, etc.)
    aerospace reinforced plastics

    MMC’s CMC’s PMC’s


    Metal Matrix Composites Ceramic Matrix Comp’s. Polymer Matrix Comp’s
    Costs of composite manufacture
    Material costs -- higher for composites
     Constituent materials (e.g., fibers and resin)
     Processing costs -- embedding fibers in matrix
     not required for metals Carbon fibers order of
    magnitude higher than aluminum
    Design costs -- lower for composites
     Can reduce the number of parts in a complex
    assembly by designing the material in
    combination with the structure
    Increased performance must justify higher
    material costs
    Forms of Reinforcement Phase
    Fibers
     cross-section can be circular, square or hexagonal
     Diameters --> 0.0001” - 0.005 “
     Lengths --> L/D ratio
     100 -- for chopped fiber
     much longer for continuous fiber
    Particulate
     small particles that impede dislication movement (in
    metal composites) and strengthens the matrix
     For sizes > 1 µ m, strength of particle is involves in load
    sharing with matrix
    Flakes
     flat platelet form
    Fibers - Glass
    Most widely used fiber
    Uses: piping, tanks, boats, sporting goods
    Advantages
     low cost
     Corrosion resistance
     Low cost relative to other composites:
    Disadvantages
     Relatively low strength
     High elongation
     Moderate strength and weight
    Types:
     E-Glass - electrical, cheaper
     S-Glass - high strength
    Fibers - Aramid (kevlar, Twaron)

    Uses:
     high performance replacement for
    glass fiber
    Examples
     Armor, protective clothing, industrial,
    sporting goods
    Advantages:
     higher strength and lighter than glass
     More ductile than carbon
    Fibers - Carbon
    2nd most widely used fiber
    Examples
     aerospace, sporting goods
    Advantages
     high stiffness and strength
     Low density
     Intermediate cost
     Properties:
     Standard modulus: 207-240 Gpa
     Intermediate modulus: 240-340 GPa
     High modulus: 340-960 GPa
     Diameter: 5-8 microns, smaller than human hair
     Fibers grouped into tows or yarns of 2-12k fibers
    Fibers -- Carbon (2)
    Types of carbon fiber
     vary in strength with processing
     Trade-off between strength and modulus
    Intermediate modulus
     PAN (Polyacrylonitrile)
     fiber precursor heated and stretched to align structure and
    remove non-carbon material
    High modulus
     made from petroleum pitch precursor at lower cost
     much lower strength
    Fibers - Others

    Boron
     High stiffness, very high cost
     Large diameter - 200 microns
     Good compressive strength
    Polyethylene - trade name: Spectra fiber
     Textile industry
     High strength
     Extremely light weight
     Low range of temperature usage
    Fibers -- Others (2)

    Ceramic Fibers (and matrices)


     Very high temperature applications
    (e.g. engine components)
     Silicon carbide fiber - in whisker form.
     Ceramic matrix so temperature
    resistance is not compromised
     Infrequent use
    Fiber Material Properties

    Steel: density (Fe) = 7.87 g/cc; TS=0.380 GPa; Modulus=207 GPa


    Al: density=2.71 g/cc; TS=0.035 GPa; Modulus=69 GPa
    Fiber Strength
    Matrix Materials
    Functions of the matrix
     Transmit force between fibers
     arrest cracks from spreading between fibers
     do not carry most of the load
     hold fibers in proper oreintation
     protect fibers from environment
     mechanical forces can cause cracks that allow environment to
    affect fibers
    Demands on matrix
     Interlaminar shear strength
     Toughness
     Moisture/environmental resistance
     Temperature properties
     Cost
    Matrices - Polymeric

    Thermosets
     cure by chemical reaction
     Irreversible
     Examples
     Polyester, vinylester
     Most common, lower cost, solvent resistance
     Epoxy resins
     Superior performance, relatively costly
    Matrices - Thermoplastics
    Formed by heating to elevated temperature at
    which softening occurs
     Reversible reaction
     Can be reformed and/or repaired - not common
     Limited in temperature range to 150C
    Examples
     Polypropylene
     with nylon or glass
     can be injected-- inexpensive
     Soften layers of combined fiber and resin and place
    in a mold -- higher costs
    Matrices - Others
    Metal Matrix Composites - higher
    temperature
     e.g., Aluminum with boron or carbon
    fibers
    Ceramic matrix materials - very high
    temperature
     Fiber is used to add toughness, not
    necessarily higher in strength and
    stiffness
    Important Note

    Composite properties are less


    than that of the fiber because
    of dilution by the matrix and
    the need to orient fibers in
    different directions.
    Material Forms and
    Manufacturing

    Objectives of material production


     assemble fibers
     impregnate resin
     shape product
     cure resin
    Sheet Molding Compound (SMC)
     Chopped glass fiber added to
    polyester resin mixture

    •Question: Is SMC isotropic or anisotropic?


    Manufacturing - Filament
    Winding

    Highly automated
     low manufacturing
    costs if high
    throughput
     e.g., Glass fiber
    pipe, sailboard
    masts
    Prepregs

    Prepreg and prepreg layup


     “prepreg” - partially cured mixture of
    fiber and resin
     Unidirectional prepreg tape with paper
    backing
     wound on spools
     Cut and stacked
     Curing conditions
     Typical temperature and pressure in
    autoclave is 120-200C, 100 psi
    Manufacturing - Layups

    compression
    molding

    vacuum bagging
    Material Forms

    Textile forms
     Braiding or weaving
     Tubular braided form
     can be flattened and cut for non-
    tubular products
    Fabric effects on material
    properties
    Resin transfer molding (RTM)

    Dry-fiber preform placed in a


    closed mold, resin injected into
    mold, then cured
    Material Forms

    Pultrusion
     Fiber and matrix are pulled
    through a die, like extrusion of
    metals -- assembles fibers,
    impregnates the resin, shapes the
    product, and cures the resin in one
    step.
     Example. Fishing rods
    Pultrusion
    Manufacturing

    Tube rolling - tubular products


     Examples
     fishing rods
     golf clubs
     oars
     Prepreg tape typically used wrapped
    in 2 directions or spiral wrapped

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