Chapter 1 Composite Materials Introduction

Composite materials are widely used in industry and engineering processes today due to their many applications and advantages. A composite material is defined as a combination of two or more materials consisting of different properties. This union essentially creates a new material with properties that are unique from the beginning components. Although they are joined together, a visible separation between the

individual materials is still present. The material utilized for this design project is carbon fibers in an epoxy matrix. It will be implemented using lamina sheets of the material. When dealing with composites, the term matrix is used to describe the material that surrounds and binds together clusters of the stronger material which, in this case, is the epoxy. The carbon fiber is known as the reinforcement material. When examined separately, carbon fiber and epoxy are quite different materials when their individual properties are viewed. The carbon fiber is made out of long, thin sheets of carbon. It is a chemically inert rigid material that is difficult to stretch and compress. On the other hand, epoxy is a

thermosetting plastic, or resin, that is liquid when prepared but hardens and becomes rigid (i.e., it cures) when is heated. The setting process is irreversible, so that it does not become soft again under high temperatures. Epoxy plastics are good at resisting wear and are highly durable when exposed to extreme environments.

The combination of these two materials into a composite has many advantages. Along with holding the fibers together, the matrix is advantageous since it protects the carbon fiber from damage by sharing any stress incurred in the element. It also provides flexibility to the otherwise rigid material which aides in shaping and molding. Composites are more versatile than metals and can be tailored to meet performance needs and complex designs. As a whole, the composite has a very high specific strength, which means it has a very high strength and low weight. In many cases, the composite is lighter than traditional materials for certain applications with comparable strength. The joining of the materials provides excellent fatigue endurance concerning the number of load cycles and residual fatigue strength that is many times higher than that of metals. In addition, the composite has good resistance against, chemicals, acids, water, and varying elements. There is very little corrosion which leads to low maintenance costs over long periods of time. The downside of composites is usually the cost. Although manufacturing processes are often more efficient when composites are used, the raw materials are expensive. Also, epoxy resins are more expensive than polyester resins and vinyl ester resins, but generally produce stronger more temperature resistant composite parts. Another usage concern is regarding the materials life-cycle. Since carbon fiber

reinforced plastics have an almost infinite lifetime, companies need to find means in which to recycle the material. The high amount of (often manual) work required to manufacture composites has limited their use in applications where a high number of complicated parts is required. Composites will never totally replace traditional materials like steel, but in many cases they are very useful. Carbon-epoxy materials are finding increased structural uses in areas such as aerospace, structural engineering, automotive, and sporting goods applications. It excels at replacing conventional materials in objects ranging from space shuttle components, bridge reinforcements, car body parts, and basketball backboards just to name a few. Furthermore, as technology evolves, new uses will be found.

The primary goal of this design project is to use the knowledge gained about composites and their advantages to create a carbon fiber / epoxy pressure vessel. The materials utilized in this project will consist of carbon / graphite fibers acting as reinforcement in an epoxy matrix formed in several layers or lamina. These materials are usually flexible, and can be molded into almost any desired shape; in this case they will

be molded into a cylinder and then baked in a kiln or high pressure oven until both materials mesh together and become a single hard structure. In order to complete this goal, a $400 budget will be used to acquire all the materials needed for design. Matrix: The primary function of the matrix is to bind the fibers together and to separate the load. If an individual fiber is broken the load is not transferred directly to the adjacent fibers, but is instead partially taken up by the matrix. This is an important feature in slowing crack propagation. The matrix material also provides some environmental protection to the fibers. Carbon or glass fibers are very strong, but also very brittle. This brittleness makes them very susceptible to wear and abrasion damage. Common matrix materials on the other hand have higher ductility and can tolerate abrasion or wear much better.