Composites

Intro to Engineering
Chemistry
Instructor: Dr. Yasir

Presented by:
Hamza Babur 150701001
Muhammad Mushtaq 150701004
Tayyaba Suleman 150701035
 Introduction
• A composite material is a material made from two or
more constituent materials with significantly different
physical or chemical properties that, when combined,
produce a material with characteristics different from
the individual components. The individual components
remain separate and distinct within the finished
structure, differentiating composites from mixtures and
solid solutions.
 Common Examples

Concrete is a mixture of cement and Plywood is used widely in construction

aggregate, giving a robust, strong
material that is very widely used.

NASA Image of Glass Reinforced

Aluminum (GLARE) Honeycomb
composite sandwich structure
• They generally have two phases:-
Matrix Phase :-
It is the continuous material constituent which encloses the
composite and give it its bulk form. Matrix phase may be metal, ceramic
or polymer.
Dispersion Phase:-
It is the structure constituent, which determines the internal
structure of composite. Dispersion Phase is connected to matrix phase by
Bonding
Why to use composite materials?

• Higher specific strength than metals, non-metals and even alloys.

• Lower specific gravity in general.
• Improved stiffness of material.
• Composite maintain their weight even at high temperatures.
• Toughness is improved.
• Fabrication or production is cheaper.
• Creep and fatigue strength is better.
• Controlled Electrical conductivity is possible.
• Corrosion and oxidation resistance.
 Background
• Earliest man made composite material was Straw and mud used to make bricks;
buildings construction.
• Brick making was first documented by Ancient Egyptians.
• Wattle and daub is one of the oldest man-made composite materials, at over 6000
years old. Concrete is also a composite material, and is used more than any other
man-made material in the world.
• Palms and Bamboo, yield natural composites that were used prehistorically by
mankind and are still used widely in construction and scaffolding.
• Plywood 3400 BC by the Ancient Mesopotamians.
• Cartonnage layers of linen or papyrus soaked in plaster dates to the First
Intermediate Period of Egypt c. 2181–2055 BC and was used for death masks.
• Concrete was described by Vitruvius, writing around 25 BC in his Ten Books on
Architecture.
• Papier-mâché, a composite of paper and glue, has been used for hundreds of years
Classification
Particle-Reinforced Composites

• Large-particle and Dispersion-strengthened composites are the two

sub classifications of particle-reinforced composites.
• The distinction between these is based upon reinforcement or
strengthening mechanism.
Large Particle Composites

• A type of particle-reinforced composite wherein particle-matrix

interactions cannot be treated on an atomic or molecular level; the
particle reinforced the matrix phase.

• For effective reinforcement, particles should be small and evenly

distributed throughout the matrix. The volume fraction of the two
phases influences the behavior; mechanical properties are enhanced
by increasing the particulates’ amount.
Rule of mixture: shows that the elastic modulus should fall between an
upper and lower bound as shown:
Structure

Electron micrograph showing the spherical reinforcing carbon black

particles in a synthetic rubber tire tread compound. The areas
resembling water marks are tiny air pockets in the rubber.
(Courtesy of Goodyear Tire &
Rubber Company.)
Material Matrix Dispersed Properties Uses

1.Concrete cement Sand & gravel Harder & stronger Construction

than plain cement purpose
2.Oxide based Cr Al2O3 Good strength & Shock resistant
cermets good shock equipment
resistance
properties
3.Carbide based Co & Ni 1.WC &TiC 1.increases surface Wire drawing,
cermets hardness dyes& machine
parts
Co & Ni 2.CrC 2. High abrasion & Valves, Spray
resistance nozzles & pump
resistance parts
4.Modern rubber Vulcanized rubber Carbon Enhancement in Used in automobile
black,(Stiffer) mechanical industry for making
properties tires
5.Spherodized steel α Iron( ductile) Fe3C Ductility of Spherical steel
cementite(brittle) composite structure for fixing
decreases tires
Dispersed Strengthened Composites

• It is a means of strengthening materials where in very small particles

of a very hard yet inert phase are uniformly dispersed within a load
bearing matrix phase.
• The dispersed phase may be metallic or non metallic, oxide materials
are often used.
• Advantage: Comparison of dispersion strengthened sintered
aluminum powder composite with that of two conventional two
phase high strength aluminum alloys.
Properties

• Very small particle of the range 10 to 100nm are used

• The particle-matrix interactions leading to strength are on atomic or
molecular level. The mechanism on strengthening in this case is
similar to that of precipitation hardening
• Matrix phases bear the major load, & particle improves yield, tensile
strength & hardness. In case of Al, the strength & hardness is
improved by the formation of extremely small uniformly dispersed
particle of dispersed particle of a second phase within the original
matrix phase with the help of heat treatments. This process is called
precipitation hardening because small particle of new phase is called
as precipitate. The procedure is also called as age hardening because
strength develops with time & as the alloy ages. E.g. the high
temperature strength of Ni alloy can be considerably enhanced by
adding about 3% by volume ThO2 in the form of dispersed particles.
Advantages of Composites Usage in Aerospace

• Weight reduction up to 20 to 50%.

• Single-shell molded structures provide higher strength at lower
weight.
• High impact resistance. For instance, Kevlar (aramid) armor shields
planes have reduced accidental damage to the engine pylons that
carry fuel lines and engine controls.
• High thermal stability
• High damage tolerance enhances accident survivability
• Resistant to fatigue/corrosion
• Structural components made of composite materials are easy to
assemble.
Fiber-Reinforced Composites
Fiber-Reinforced Composites

• Fiber-reinforced composites are composed of axial

particulates(Dispersion material) embedded in a matrix material
• To obtain a material with high specific strength and high specific
modulus
• Interfacial bonding is important for strength.
• Classic examples of fiber-reinforced composites include fiberglass and
wood
Fiber Geometry

• Aligned Adapted from Fig. 16.8,

• Highly anisotropic properties Callister & Rethwisch 8e.

• The longitudinal tensile strength will be

high whereas the transverse tensile
strength can be much less than even
the matrix tensile strength
• transverse tensile strength will depend
on the properties of the fibers and the
matrix, the interfacial bond between
them, and the presence of voids
aligned aligned random
continuous discontinuous
Fiber Geometry

• Continuous & Aligned

• The fibers are longer than a critical length which is the minimum length
necessary such that the entire load is transmitted from the matrix to
the fibers
• If they are shorter than this critical length, only some of the load is
transmitted
• Fiber Length > 15 time the Critical Length
• Provide the most effective strengthening for fiber composites
Fiber Geometry
• Aligned Continuous fibers
• Examples:
-- Metal: g'(Ni3Al)-a(Mo).
matrix: a (Mo) (ductile)
2 mm
fibers: g ’ (Ni3Al) (brittle)
From W. Funk and E. Blank, “Creep
deformation of Ni3Al-Mo in-situ
composites", Metall. Trans. A Vol. 19(4),
pp. 987-998, 1988.
Ceramic: Glass w/SiC fibers.
(a fracture
) surface
From F.L. Matthews and R.L.
Rawlings, Composite Materials;
Engineering and Science, Reprint
(b
ed., CRC Press, Boca Raton, FL,
2000. (a) Fig. 4.22, p. 145 (photo by
J. Davies); (b) Fig. 11.20, p. 349
) (micrograph by H.S. Kim, P.S.
Rodgers, and R.D. Rawlings
Fiber Geometry

• Discontinuous & Aligned

• The fibers are shorter than the critical length
• Less effective in strengthening the material
• Cheaper, faster and easier to fabricate into complicated shapes
• Random
• Also called discrete, (or chopped) fibers
• Strength will not be as high as with aligned fibers
• The advantage is that the material will be isotropic and cheaper
Fiber Geometry

• Discontinuous fibers,
• Example: Carbon-Carbon C fibers:
very stiff
very strong
(b
C matrix:
) 500 mm
less stiff
view onto plane less strong
fibers lie
(a in plane
)

Adapted from F.L. Matthews and R.L. Rawlings,

Composite Materials; Engineering and Science,
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. Davies)
Fiber Cross Section

• The fiber cross sectional

shape and size is very
important
• As the critical length is
dependent on the diameter
Fiber Cross Section

• Critical fiber length for effective stiffening & strengthening:

fiber ultimate tensile strength fiber diameter
d
fiber length  f shear strength of
2c fiber-matrix interface
• Ex: For fiberglass, common fiber length > 15 mm needed

Short, thick fibers: Long, thin fibers:

d d
fiber length  f fiber length  f
2 c 2c

Low fiber efficiency High fiber efficiency

Fiber Phase

Some general categories of fibers phase :

• Whiskers
• very small diameter (~1 micron) single crystals
• strong because they are virtually flaw free
• expensive
• difficult to put in a matrix
• examples include graphite (C), SiN, Al2O3, SiC
• Fibers
• small diameters (~10 microns)
• can be polycrystalline or amorphous
• Wires
• large diameters (~25 microns)
• made from metals such as steel, Mo, W
Matrix Phase

In general the purpose of the matrix phase is:

• to transfer the load to the fibers
• prevent propagation of brittle cracks
• separate the fibers and protect them from surface damage
• matrix is reasonably ductile
Composites based on the Matrix Material

• PMC - Polymeric Matrix Composites

• These are relatively cheap and easy to Polyesters
fabricate. Their service temperatures are
<200°C
• Very ductile
• Examples include:
• polyesters (cheap)
• vinyl esters (cheap)
• epoxies (more expensive but better properties Thermoplastic
and more resistant to moisture) Resin
• polyimide resins (for relatively high temps)
• thermoplastic resins (for high temps)
Applications of PMC

• Epoxy resin are used for coating the floors

• Consumer Plastic Products
• Premium resins such as isophthalic and vinyl ester formulations are
used for corrosion resistance specifications
• Industrial uses includes, underground storage tanks, scrubbers,
piping, fume hoods, water treatment components, pressure vessels
• Kevlar is used under Military and Space applications
Composites based on the Matrix Material

• MMC - Metal Matrix Composites

• high strength-to-weight ratios
• better performance at high temperatures
• better conductivities
• non-flammable
• greater resistance to degradation by organic fluids
• good ductility and good load bearing capabilities
• more expensive
Composites based on the Matrix Material

• MMC Cont.
Composites based on the Matrix Material

• CMC - Ceramic Matrix Composites

• Developed to get improved strength and toughness for high temperature
applications
• Tensile & Compressive Behavior
• Fracture Toughness
• Fatigue Resistance
• Thermal Response
• Chemical Inertness
• Corrosion Resistance
Applications of CMC

• Aerospace
Applications of CMC

Cutting Tools Burner

Applications of CMC

Turbine Blades
Other Fiber-Reinforced Composits

• CARBON–CARBON COMPOSITES
• employed in
• rocket motors
• as friction materials in aircraft and high-performance automobiles
• for hot-pressing molds
• in components for advanced turbine engines
• as ablative shields for re-entry vehicles
• HYBRID COMPOSITES
• Two or more different kinds of fibers in a single matrix
• Principal applications for hybrid composites are lightweight land, water, and
air transport structural components
Structural composites
Introduction
• A structural composite is normally composed of both homogeneous
and composite materials.
• The properties of structural composites depend not only on the
properties of the constituent materials but also on the geometrical
design of the various structural elements.
• Two types of structural composites are
1. Laminar composites
2. Sandwich panels
Laminar Composites
• A laminar composite is composed of two-dimensional sheets or
panels that have a preferred high-strength direction such as is found
in wood and continuous and aligned fiber-reinforced plastics.
• The layers are stacked and subsequently cemented together such
that the orientation of the high-strength direction varies with each
successive layer.
• Wood sheets is an example of this composite.
• In wood sheets in plywood the grain direction is at right angles.
• Other laminar composites can be made from cotton, paper, or woven
glass fibers embedded in a plastic matrix.
The stacking of successive oriented, fiber-reinforced layers for a
laminar composite.
Sandwich panels

• Another type of structural composite is sandwich panel.

• These are designed to be light-weight beams or panels having
relatively high stiffness and strengths.
• A sandwich panel consists of two outer sheets, or faces, that are
separated by and adhesively bonded to a thicker core.
• The outer sheets are made of a relatively stiff and strong material,
typically aluminum alloys, fiber-reinforced plastics, titanium, steel, or
plywood; they impart high stiffness and strength to the structure,
and must be thick enough to withstand tensile and compressive
stresses that result from loading.
Schematic diagram
showing the cross
section of a sandwich
panel.
Core of the sandwich panel
• The core material is lightweight, and normally has a low modulus of
elasticity. Core materials typically fall within three categories: rigid
polymeric foams (i.e., phenolics, epoxy, polyurethanes), wood (i.e.,
balsa wood), and honeycombs.
• The core has several functions such as
1. it provides continuous support for the faces.
2. it must have sufficient shear strength to withstand transverse shear
stresses.
• The honey comb material is normally either an aluminum alloy or
aramid polymer.
• The cell size, cell wall thickness and the material from which the
honeycomb is made determines the strength and stiffness of the
structure.
• Sandwich materials are widely used in roofs, floors and walls in
buildings, aerospace and aircraft (for wings, fuselage, and tailplane
skins.)
Nano-Composites
• These are the materials that have Nano-sized particles embedded in
some type of matrix.
• These are the future of the modern age technologies.
• Currently Nano-composites are being used in tennis balls.
• This nanocomposite coating consists of a matrix of butyl rubber,
within which is embedded thin platelets of vermiculite, a natural clay
mineral.