COMPOSITE

MATERIALS
 COMPOSITES
-Composite materials are engineered materials made
from two or more constituent materials that remain
separate and distinct while forming a single component

-Generally, one material forms a continuous matrix while

the other provides the reinforcement

- The two materials must be chemically inert with respect

to each other so no interaction occurs upon heating until
one of the components melts, an exception to this
condition is a small degree of interdiffusion at the
reinforcement-matrix interface to increase bonding
 COMPOSITES
Composites can be found in:
-Boat hulls
-The aerospace industry (structural components as well
as engines and motors)
-Automotive parts (panels, frames, dashboards, body
repairs)
-Sinks, bathtubs, hot tubs, swimming pools
-Cement buildings, bridges
-Surfboards, snowboards, skis
-Golf clubs, fishing poles, hockey sticks
-Trees are technically composite materials, plywood
-Electrical boxes, circuit boards, contacts
-Everywhere
 COMPOSITES
Composites can be classified by their
matrix material which include:
-Metal matrix composites (MMC’s)

-Ceramic matrix composites (CMC’s)

-Polymer matrix composites (PMC’s) or

sometimes referred to as organic matrix
composites (OMC’s)
 COMPOSITES
MMC - Metal Matrix Composites
-The matrix is relatively soft and flexible.
-The reinforcement must have high strength and stiffness
-Since the load must be transferred from the matrix to the
reinforcement, the reinforcement-matrix bond must be strong.

MMC use:
-Two types of particulates ( dispersion strengthened alloys
and regular particulate composites)
-Or long fiber reinforcements
 COMPOSITES
PMC - Polymer Matrix Composites
-The matrix is relatively soft and flexible
-The reinforcement must have high strength and stiffness
-Since the load must be transferred from matrix to
reinforcement, the reinforcement-matrix bond must be strong

CMC – Ceramic Matrix Composites

-The matrix is relatively hard and brittle
-The reinforcement must have high tensile strength to arrest
crack growth
-The reinforcement must be free to pull out as a crack extends,
so the reinforcement-matrix bond must be relatively weak
 Classification based on
reinforcement
 Fibre reinforced composites
 Particle reinforce composites
 Structural composites
 Hybrid composites
Types of Composite Materials
There are five basic types of composite materials: Fiber,
particle, flake, laminar or layered and filled composites.
 FIBER REINFORCED
COMPOSITES
-Fiber reinforced composites provide improved strength,
fatigue resistance, Young’s modulus and strength to
weight ratio over the constituent materials.

-This is achieved by incorporating strong, stiff, yet brittle

fibers into a more ductile matrix.

-Generally speaking the fiber supplies the strength and

stiffness while the matrix binds the fibers together and
provides a means of transferring the load between fibers

-The matrix also provides protection for the fibers

 CHARACTERISTICS OF FIBER
REINFORCED COMPOSITES

-Many factors must be considered when designing a fiber-

reinforced composite including the length, diameter, orientation,
amount and properties of the constituents, and the bonding
between them.

-The method used to produce the final product is also very

important as it dictates the type of properties just mentioned as
well as the quality of the product.
 CHARACTERISTICS OF FIBER
REINFORCED COMPOSITES
Fiber length and diameter: Fiber dimensions are characterized by
their aspect ratio l/d where l is the fiber length and d is the
diameter.
The strength improves when the aspect ratio is large.
Typical fiber diameters are from 10 m to 150 m.
Fibers often fracture because of surface imperfections. Making
the diameter small reduces its surface area, which has fewer
flaws.
Long fibers are preferred because the ends of the fiber carry less
of the load. Thus the longer the fiber, the fewer the ends and the
higher the load carrying capacity of the fibers.
 FIBER ORIENTATION

-Maximum strength is
obtained when long fibers are
oriented parallel to the
applied load
-The effect of fiber orientation
and strength can be seen in
the plot
 FIBER ORIENTATION

-The properties of fiber

composites can be
tailored to meet different
loading requirements
-By using combinations of
different fiber orientation
quasi-isotropic materials
may be produced

Figure (a) shows a unidirectional arrangement

Figure (b) shows a quasi-isotropic arrangement
 FIBER ORIENTATION

-A three dimensional
weave is also possible

-This could be found

when fabrics are knitted
or weaved together
 B. Particle Composites
 Particles usually reinforce a composite equally in all directions (called
isotropic). Plastics, cermets and metals are examples of particles.
 The volume of these particles usually 25 -50% of the volume
 Particles used to strengthen a matrix do not do so in the same way
as fibers. For one thing, particles are not directional like fibers.
Spread at random through out a matrix, particles tend to reinforce in
all directions equally.

 Cermets
(1) Oxide–Based cermets
(e.g. Combination of Al2O3 with Cr)
(2) Carbide–Based Cermets
(e.g. Tungsten–carbide, titanium–carbide)
 Metal–plastic particle composites
(e.g. Aluminum, iron & steel, copper particles)
 Metal–in–metal Particle Composites and
Dispersion Hardened Alloys
(e.g. Ceramic–oxide particles)
 Structural Composites
 Laminar composites
 2-d sheets or panels
 Stacked and bound with orientation in
altering directions
 Improved strength in 2 or more
directions in 2d, but not 3d.
 Sandwich Panels
 Face sheets with uniform strength are
separated by a core or honeycomb.

face sheet
adhesive layer
honeycomb
 Hybrid composites
 It consist of two or more types of fibers embedded in
a common matrix.
 They provide dimensional stability, less weight and
improve fatigue and fracture resistance.
 These are used for sporting goods and light weight
orthopedic components.
 The most common hybrid composites are carbon-
aramid reinforced epoxy (which combines strength
and impact resistance) and glass-carbon reinforced
epoxy (which gives a strong material at a reasonable
price).
 COMMERCIALLY AVAILABLE
FORMS OF REINFORCEMENT

Above Left: Roving

Above Right: Filaments
Right: Close up of a roving
COMMERCIALLY AVAILABLE
FORMS OF REINFORCEMENT

Random mat and woven fabric

(glass fibers)
 COMMERCIALLY AVAILABLE
FORMS OF REINFORCEMENT

Carbon fiber woven fabric

glass-carbon reinforced epoxy

 MANUFACTURING OF
COMPOSITES
Hand Lay-Up/Spray-Up
-Oldest and most commonly used manufacturing method
-Usually used to produce polyester or epoxy resin parts such as boat
hulls, tanks and vessels, pick-up truck canopies
-The method is quite simple, the resin and reinforcement is placed
against the surface of an open (one sided) mold and allowed to cure or
in the case of spray-up the resin/reinforcement is sprayed onto the
mold with a spray gun
-Often a gel coat is applied to the mold prior to
produce a better surface quality and protect the
composite from the elements
-A gel coat is a resin usually 0.4 to 0.7 mm
thick, commonly seen on the outer surface of
smaller boats
 Continuous protrusion process
 Continuous protrusion: Continuous strand fibers
are impregnated in resin bath, fed into heated
die and drawn.
 Used to produce beams, channels,and pipes.
MANUFACTURING OF
COMPOSITES
Filament Winding
 The fibres are fed through a resin bath and
the feeding mechanism traverses the
length of the mandrel.
 The layers of fibre are applied to form the
required thickness of the laminate. The
mandrel rotating speed and the traversing
speed dictate the fibre winding angle.
 The cure process is generally initiated
once the winding is complete either by
heating the mandrel while it is still on the
machine or by removing it and placing the
part in an oven.
MANUFACTURING OF
COMPOSITES
Filament Winding
 MANUFACTURING OF
COMPOSITES
Resin Transfer Molding
-Resin transfer molding is a manufacturing method that is
quite similar to injection molding where plastic is injected
into a closed mold
-In the RTM process the preform (precut piece(s) of
reinforcement) is placed in the mold, the mold is closed
and the thermoset plastic matrix is injected into the mold,
once the matrix is cured the part is ejected
MANUFACTURING OF
COMPOSITES
Resin Transfer Molding
 Vacuum-Bag Molding
 Pre-impregnated fiber is applied to the mould either by hand or machine.
 The fiber area is covered with a rubber or plastic bag and the air removed using a vacuum pump.
 Further pressure and increased temperature are applied by placing the mould in an oven or
autoclave and the resin is cured.
 Under the applied pressure, the layers of prepreg are fused together and any excess resin
removed. The vacuum allows for voids to be collapsed producing a laminate with a very low void
content.
 The release mechanism consists of a special film applied to each surface which allows air and
excess resin to pass through it.
 The main advantage of this manufacturing method is that components of high quality with
excellent properties can be produced. This is still the favoured method of the aerospace industry.