SELVAM COLLEGE OF TECHNOLOGY, NAMAKKAL 03 Ph: 9942099122

DEPARTMENT OF MECHANICAL ENGG.| COMPOSITE MATERIALS IV YEAR (7th SEMESTER)

Two Marks Questions and Answer Unit-I 1. What are the major constituents in composite materials? Reinforcing phase. One in which it is embedded is called the matrix. Reinforcing phase - Fibres, particles or flakes. Matrix - Materials are generally continuous. 2. Define lamina. A lamina (also called a ply or layer) is a single flat layer of unidirectional fibres or woven fibres arranged in a matrix. 3. Define laminate. A laminate is a stack of plies of composites. Each layer can be laid at various orientations and can be different material systems. 4. Define Hooke's law. Within elastic, stress is proportional to strain. e.g., Spring balance. 5. What are advanced composites? Advanced composites are composite materials which are traditionally used in the aerospace industries. These composites have high performance reinforcements of a thin dia. in a matrix material such as epoxy and aluminum. 6. List down the reinforcement materials and resins used in composite materials. Reinforcement materials. Graphite, Glass, Aramid, Kevlar 49, Boron. Resins Epoxy, Aluminium, Polyamide, Nylon, Polyesters, Vinyl esters, Phenolics. Polymides, Polybenzimidazoles, Polyphenylquinoxaline. (ii) Fixed fibre volume in a given volume of composite, the area of the fibrematrix interface is inversely proportional to the diameter of the fibre. (iii) Ability to bend increases with a decrease in the fibre diameter and is measured as flexibility. 8. What are the aircraft structural components made of composite materials? (i) Elevator face sheets, Horizontal stabilizer, Wing spoilers, ailerons, rudders, elevators, fairings etc., (ii) Skin on the horizontal stabilizer box, Under wing fairings, fin, rudder and stabilizer skins, skins on vertical fin box, fin leading edge, wing skins, horizontal and vertical tail boxes. 9. What are the properties of matrices? Properties: Low viscosity. High melting point. Low curing temperature. 10. Define composite material. A composite is a structural material which consist s of combining two or more constituents. The constituents are combined at a macroscopic level and are not soluble in each

SELVAM COLLEGE OF TECHNOLOGY, NAMAKKAL 03 Ph: 9942099122

DEPARTMENT OF MECHANICAL ENGG.| COMPOSITE MATERIALS IV YEAR (7th SEMESTER)

other. One constituent is called the reinforcing phase and the one in which it is embedded is called matrix. 11. Write four applications of composite materials? Air craft, Space, Automotive, Sporting goods Marine engineering. 12. Distinguish between long fibres and short fibres. Long fibres: Easy to orient & process. I resistance, low shrinkage, improved surface finish dimensional stability. Short fibres: Low cost, Easy to work with matrix Short fibres have few flaws, and therefore have higher strength.

13. What is a particulate composite? It consists of particles immersed in matrices such as alloys and ceramics. They are usually isotropic since the particles are added randomly. 14. Explain the difference between fibres and whiskers. Fibre: A fibre is characterized geometrically not only by its very high length to diameter ratio but by its near crystal sized diameter. Whiskers: A whisker has essentially the same near-crystal- sized diameter as a fibre but generally is very short and stubby, although the length-to-diameter ratio can be in the hundreds. Thus a whisker is an even more obvious example of the crystal-bulk-materialproperty difference paradox. 15. What is meant by sizing of glas sfibres? The filaments are cooled rapidly and coated with a sizing such as starch, gelatin, oil, etc., to avoid damage to the fibres. The sizing imparts strand integrity, resin compatibility, adhesion properties, etc., to the final product. Unit-II 1. What is meant by fibre? Principal load carrying member. Main constituent and occupy largest volume fraction. The diameter of a fibre will be around 10 urn. Commercially available fibres are of various types, such as glass, carbon and Kevlar. Fibres may be of continuous or discontinuous in length. 2. What are the major constituents of composite materials? Fibre Matrix Fillers Coupling agents and Coatings. 3. What is meant by lamina? A single ply or layer in a laminate made of a series layers. 4. What is meant by resin? An organic material with indefinite and usually molecular weight and no sharp melting point.

SELVAM COLLEGE OF TECHNOLOGY, NAMAKKAL 03 Ph: 9942099122

DEPARTMENT OF MECHANICAL ENGG.| COMPOSITE MATERIALS IV YEAR (7th SEMESTER)

5. Define matrix. The essentially homogenous material in which fibres or filaments of composite are imbedded. Fibres are reinforced inside the matrix. Acts as a load transfer medium. Keeps fibres in desired location and orientation. 6. Discuss the applications of composites. In the field of military and commercial air craft [weight reduction and dynamic frequency tailoring]. Carbon fibres and Kevlar 49 used in wing, fuselage and empennage components. Fibre reinforced epoxies are used in rotor blades for military and commercial helicopter, i.e., manufacturing flexibility. Kevlar 49 or S-glass fibre reinforced epoxies used in filament wound motor cases. 7. Define fibre orientation. Fibre orientation in each layer as well as stacking sequence of the plies plays a major role in the strength and modulus of the composite laminates. 8. What are the polymeric matrixes used in composites? Epoxy, polyester, phenolic, acrylic, urethane and polyamide. 9. What are the functions offibres? Carry load along the length of the fibre provides strength and stiffness in one direction. Can be oriented to provide properties in directions of primary loads. 10. What are the types of fillers? Calcium carbonate Clay Talc Aluminium Trihydrate Silica Micro spheres Mica 11. What are types of additives? Catalysts and promoter Inhibitors Release agent Pigments UVabsorber Fire retardancy 12. Define adhesive. A substance capable of holding two materials together surface attachment. The term is used specifically to designate structural adhesives, those .which prodjj adhesion capable of transmitting significant structural loads.

SELVAM COLLEGE OF TECHNOLOGY, NAMAKKAL 03 Ph: 9942099122

DEPARTMENT OF MECHANICAL ENGG.| COMPOSITE MATERIALS IV YEAR (7th SEMESTER)

13. What are the different types offibres? The following types of fibres are, Glass fibres Silicon fibres Alumina fibres Carbon or graphite fibres Boron fibres Kevlar fibres Aramid fibres Metal fibres Wire fibres 14. Mention four advantages and disadvantages of glass fibres .. Advantages: Low cost High tensile strength I High chemical resistance Excellent insulating properties. Disadvantages: Low tensile modulus High specific gravity High hardness Sensitivity to abrasion with handling 15. What are the applications of glass fibres? Military and aerospace products Optical devices Radomes Helicopter rotor blades Ballistic Production of composite panels Asbestos replacement 16. Discuss the different types of glass fibres? E-glass - "E" stands for electrical S-glass - "S" stands for high silica content o High thermal expansion coefficient o High fatigue strength C-glass - "C" stands for corrosion o Used in chemical applications o Storage tanks

18. Define cross ply. Any filamentary lamina which is not uniaxial.

SELVAM COLLEGE OF TECHNOLOGY, NAMAKKAL 03 Ph: 9942099122

DEPARTMENT OF MECHANICAL ENGG.| COMPOSITE MATERIALS IV YEAR (7th SEMESTER)

19. What are the properties of glassfibres? High production rates High strength High stiffness Relatively low density Good electrical resistance Good chemical resistance Resistant to heat 20. What are the advantages and disadvantages of carbon fibre? Advantages: High tensile strength to weight ratio. Low cost. Low specific gravity. Low coefficient of thermal expansion. Disadvantages: Low impact resistance. High electrical conductivity. 21. What is meant by carbon filter? While use of the term carbon for graphite is permissible, there is one basic difference between the two. A common method of making carbon filaments is the oxidation and thermal pyrolysis of polyacrylonitrile (PAN), a polymer used in the creation of many synthetic materials. 22. What are the applications of carbon fibre? Aerospace Sporting goods Cargo bag doors Booster rocker casing Turbine blade Compressor blade Wind mill blade Flywheel 23. What are the properties of carbon fibre? High tensile strength Weight Thermal expansion Fatigue life Acoustical insulation Unit-III 1. What is meant by polymer matrix composites? A polymer is defined as a long chain moleculecontaining one or more repeating units of atom, joined together by strong covalent bonds. A polymeric material is a collection of a large number of polymer molecules of similar chemical structure (but not of equal length).

SELVAM COLLEGE OF TECHNOLOGY, NAMAKKAL 03 Ph: 9942099122

DEPARTMENT OF MECHANICAL ENGG.| COMPOSITE MATERIALS IV YEAR (7th SEMESTER)

2. What are the drawbacks of polymer matrix composites? PMC include low operating temperature high co-efficient of thermal and moisture expansion and low elastic, properties in certain direction. 3. What are various types of polymers used in the advanced polymer composites? These polymers include epoxy, phenolic, acrylic. urethane and polyamide. 4. What is the function of matrix resins? (i) Provide a uniform distribution of the structural and environmental load to the reinforcing fibre through a good adhesion to and a strong interface with the reinforcement. (ii) Absorb the impact of loads and minimize stress concentrations by enhancing the fracture toughness. 5. What are the classifications of resins? (i) Based on the thermoplastic resins Polyethenic resins Polyethylene Polypropylene Polystyrene Polycarbonates ABS polymer resins (ii) Based on the thermoset resins Epoxy resins Phenolic resins Polyester resins Polyurethanes Alkyd resins 6. What is meant by molecular composites? Molecular composites may be regarded as rigid rod polymeric materials as reinforcements, dispersed in a random coil polymer matrix. The high lid ratio or aspect ratio of the reinforcement is expected to impart high modulus and high tensile strength to the system. 7. What are the factors contributing the thermoplastic resins? Factors contributing to this objective are, Long prepreg stability without the need for. refrigeration. Fast processing cycle. r: Ease of quality control. High damage tolerance characteristics. 8. Give the preparation of molding compounds. (i) Resin (ii) Plasticizers (iii) Fillers (iv) Lubricants (v) Catalysts (vi) Stabilizers (vii) Coloring materials

SELVAM COLLEGE OF TECHNOLOGY, NAMAKKAL 03 Ph: 9942099122

DEPARTMENT OF MECHANICAL ENGG.| COMPOSITE MATERIALS IV YEAR (7th SEMESTER)

9. Define shelf life. Shelf life of adhesive means the time from the date of manufacture to the termination of life of adhesive due to its determination by ageing process. 10. What are the types of open mould process? Spray lay-up Hand lay-up Filament winding Sheet molding compound Contact molding 11. What are the types of close mould process? Compression molding Vacuum bag Pressure bag Autoclave Injection molding 12. What are the advantages of open mould process? Freedom to design Easy to change design Low mould and tooling cost Tailored properties possible 13. What are the disadvantages of open mould process? Low to medium number of parts Long cycles times per molding ". Operator skill depended 14. Define specific flexural rigidity. It is the ratio between flexural rigidity and weight. 15. Mention the disadvantages of filament winding. Difficulty to wind complex shapes Poor external finish Limited to convex shape component 16. Define prepreg. A combination of mat, fabric, non woven material, or roving with resin, usually advanced to the B-stage, ready for curing. 17. Define resin. An organic material with indefinite and usually high molecular weight and no sharp melting point. 18. Name one thermoplastic and one thermosetting resin used as matrix material for polymer composites. Thermoplastic resin - Polyethylene, polycarbonates resin. Thermosetting resin - Epoxy, polyester resin.

SELVAM COLLEGE OF TECHNOLOGY, NAMAKKAL 03 Ph: 9942099122

DEPARTMENT OF MECHANICAL ENGG.| COMPOSITE MATERIALS IV YEAR (7th SEMESTER)

19. What are the advantages and disadvantages of Hand lay-up method? Advantages: Design Flexibility Tooling cost is low Semi-skilled workers are needed Disadvantages: Low volume process Longer cure times required The waste factor can be high 20. Mention the applications of hand lay-up method? Standard wind-turbine blades Production boats Architectural moldings Auto and truck body parts Furniture and accessories 21. What is meant by Hand lay-up method? The hand lay-up is one of the oldest and most commonly used methods for manufacture of composite parts. Hand lay-up composites are a case of continuous fibre reinforced composites. Layers of unidirectional or woven composites are combined to result in a material exhibiting desirable properties in one or more directions. 22. What is meant by Prepreg method? It is considerable number of prepregs available as epoxy 'B' staged glass or carbon reinforced cloth. The first step prior to prepreg application on the master surface is to ensure that the prepreg and the master surface are absolutely clean and free from debris and that the surface is smooth and without pin holes. Unit-IV 1. Define laminate. It is defined as he product made by bonding together two or more layers or laminate of materials is called laminate. 2. What is meant by anisotropic material? Anisotropic is not isotropic having mechanical and physical properties which vary with direction relative to the natural reference axis inherent in the material. 3. What are four elastic moduli of a unidirectional lamina? Longitudinal young's modulus, Transverse young's modulus, Major Poisson ratio, In plane shear modulus. 4. What are failure of unidirectional ply under longitudinal tensile load? Brittle fracture of fibres, Brittle fracture of fibres with pull out, Fibre pull out with fibre matrix debonding. 5. Define Macromechanics. Macromechanics is the study of composite material behavior where in the material is presumed homogeneous and the effects of the constituent materials are detected only as averaged apparent macroscopic properties of the composite materials.

SELVAM COLLEGE OF TECHNOLOGY, NAMAKKAL 03 Ph: 9942099122

DEPARTMENT OF MECHANICAL ENGG.| COMPOSITE MATERIALS IV YEAR (7th SEMESTER)

6. Define micromechanics. Micromechanics is the study of composite material behavior where in the interaction of the constituent materials is examined on a microscopic scale to determine their effect on the properties of the composite materials. 7. Define material utilization factor. It is the ratio of raw material weight to the final part weight. 8. What is meant by homogeneous material? A homogeneous body has material properties throughout i.e., the properties are independent of position in the body. 9. Define Isotropic material. An isotropic body has material properties that are the same in every direction at a point in the body i.e., the properties are independent of orientation at a point in the body. 10. Define Orthotropic material. An orthotropic body has material properties that are different in three mutually perpendicular directions at a point in the body and further has three mutually perpendicular planes of material property symmetry Thus; the properties depend on orientation at a point in the body. 11. What are the assumptions of unidirectional lamina? The basic assumptions in this vastly simplified approach are as follows, Fibres are uniformly distributed throughout the matrix. The matrix is free of voids. Both fibres and matrix behave as linearly elastic materials. Perfect bonding exists between fibres and matrix. 12. What are steps followed in lamination theory? Calculation of stiffness matrix for the lamina. Calculation of mid-plane strains and curvatures for the laminate due to a given set of applied forces a,nd moments. Unit-V 1. What are adhesive bonded joints? Lap joint, Butt joint, Angle joint, Corner joint. 2. What are types of hybrid laminate? Interply hybrid laminate, interply hybrid laminate, interply-intraply, resin hybrid laminate. 3. What are the advantages of bonded structures? Improved fatigue Crack arresting Weight Saving 4. What is hybrid laminate? Hybrid Composite contain either more than one fibre are one matrix system in laminate. 5. What is meant by particulate composite? Particulate Composite materials consist of particles of one or more materials suspended in a matrix of another material. The particles can be either metallic or non metallic as can the matrix.

SELVAM COLLEGE OF TECHNOLOGY, NAMAKKAL 03 Ph: 9942099122

DEPARTMENT OF MECHANICAL ENGG.| COMPOSITE MATERIALS IV YEAR (7th SEMESTER)

6. Define fatigue. Fatigue is a progressive and localized structural damage that occurs when a material is subjected to cyclic loading. Fatigue occurs when a material is subjected to repeated loading and unloading. 7. What is meant by adhesive? A substance capable of holding two materials together by surface attachments. The term is used specifically to designate structural adhesives, those which produce adhesion capable of transmitting significant structural loads. 8. Define fatigue life. Fatigue life is defined the number of stress cycles of a specified character that a specimen sustains before failure of a specific nature occurs. 9. What are the characteristics offatigue? Fatigue life scatter tends to increase for longer fatigue lives. Damage is cumulative material do not recover when rested. 10. What are the factors affecting the fatigue-life? Cyclic stress state. Geometry. Material type. Grain Size. Temperature. Direction of loading. Residual stresses. 11. What are the classifications of Composite structure? Fibre Reinforced. Dispersion strengthened. Particle Reinforced. 12. Define Composite structural design. A Composite structural design can be defined as the process of finding an optimum configuration with structural dimensions and materials to support the given load and to economically perform the assigned task. 13. What are the material selections in composite structure design? Strength. Cost. Marine biological attack. Testing requirement. Electrical properties Fatigue life Specific density Stiffness Weight. Chemical resistance

SELVAM COLLEGE OF TECHNOLOGY, NAMAKKAL 03 Ph: 9942099122

DEPARTMENT OF MECHANICAL ENGG.| COMPOSITE MATERIALS IV YEAR (7th SEMESTER)

15. What are the two types of Joints for laminate Composites? 1. Mechanical fastened Joints. 2. Adhesive or bonded Joints. 16. List any two advantages and disadvantages of Mechanical fastened Joints or bolted Joints? Advantages: Positive connection No thickness lamination. Disadvantages: Large weight penalty. Prone to Corrosion. 17. What are failure criteria in bolted Joints? Tension or tearing failure. Shear out failure. Bearing failure. Cleavage failure. 18. What are the requirements of fastener selection for joining composite structures? Corrosion compatibility. Fastener material. Bolt Bending. Head configuration. Clamp up. 19. What is meant by bonded joints? Adhesive joints or bonded joints are capable of high structural efficiency and constitute a resource for structural weight saving because of the potential for elimination of stress concentrations, which cannot be achieved with mechanical fastened joints.