A07 - Introduction to Composite Materials

Introduction to Composite Materials References

AERO 304 notes and Introduction to Aerospace Structural Analysis, Allen and Haisler

Principles of Composite Material Mechanics, R. . !i"son, Mc!ra#-Hill, 1$$4 Mechanics of Composite Materials, Ro"ert M. %ones, Mc!ra#Hill, 1$7& Introduction to Composite Materials, '.(. )sai and H.). Ha*n, )ec*nomic +u"lis*in, Co., 1$-0 Introduction and Terminology 'tructural materials can "e di.ided into 4 "asic cate,ories/ Metals +ol0mers Ceramics

A07 - Introduction to Composite Materials

Composites Composites, #*ic* consist o2 t#o or more separate materials com"ined in a macroscopic structural unit, are made 2rom .arious com"inations o2 t*e ot*er t*ree materials. )*e relati.e importance o2 t*e 2our "asic materials in a *istorical conte3t *as "een presented "0 As*"0 4)ec*nolo,0 o2 t*e 1$$0s/ Ad.anced Materials and +redicti.e 5esi,n, M. . As*"0, Philosophical Transactions of the Royal Society of London, A311, 3$3-407, 1$-76 and is s*o#n sc*ematicall0 "elo# 42i,ure ta7en 2rom !i"son6/

A07 - Introduction to Composite Materials

A07 - Introduction to Composite Materials

Man7ind *as used composites since earl0 time8 2or e3ample, stra#rein2orced cla0 "ric7s used "0 Israelites 4t*e "oo7 o2 E3odus in t*e Old Testament6, plant 2i"er-rein2orced potter0, etc. )*e0 7ne# 2rom dail0 use t*at 2i"er rein2orcement o2 a material is .er0 e22ecti.e "ecause man0 materials 4"ut not all6 are muc* stron,er and sti22er in 2i"er 2orm t*an t*e0 are in "ul7 2orm. or e3ample, !ri22it* 2ound t*at as ,lass rods and 2i"ers ,ot t*inner, t*e0 ,ot stron,er. He 2ound t*at t*at 2or .er0 small diameters t*e 2i"er stren,t* approac*ed t*e t*eoretical co*esi.e stren,t* "et#een ad9acent la0ers o2 atoms, #*ereas 2or lar,e diameters t*e 2i"er stren,t* dropped to near t*e stren,t* o2 "ul7 ,lass. i"ers allo# one to o"tain t*e ma3imum tensile stren,t* and sti22ness o2 a material, "ut t*ere are disad.anta,es. i"ers alone cannot support lon,itudinal compressi.e loads and t*eir trans.erse mec*anical properties are ,enerall0 not as ,ood as t*e

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correspondin, lon,itudinal 42i"er direction6 properties. )*us, t*ere is o2ten t*e need to place 2i"ers in di22erent directions dependin, upon t*e particular loadin, application. Types of Fiber-Reinforced Composites One ,enerall0 2inds 2our t0pes o2 2i"er-rein2orced composites as s*o#n "elo# 42rom !i"son6. )*e0 di22er in *o# t*e 2i"ers are utili:ed to ma7e t*e composite 4orientation and len,t* o2 2i"ers6.

A07 - Introduction to Composite Materials

A07 - Introduction to Composite Materials

Continuous 2i"er composites are ,enerall0 <laid-up< in plies 4or laminae6 #it* eac* pl0 *a.in, 2i"ers oriented in t*e same direction. A la0er o2 2i"ers all oriented in t*e same direction is im"edded in a *omo,eneous material 4called t*e matrix6 to ma7e a sin,le pl0 or laminae. or e3ample, ,lass-epo30 *as a la0er o2 ,lass 2i"ers runnin, more-or-less parallel #it*in an epo30 resin matri3 material. Indi.idual plies can "e stac7ed or la0ered and "onded to,et*er #it* indi.idual pl0 2i"er directions "ein, selected so as to tailor t*e la0-up 4or laminate6 to *a.e desired o.erall structural c*aracteristics o2 t*e laminate. =nder loadin,, t*e potential 2or delamination 4or separation o2 t*e laminae6 is a ma9or pro"lem "ecause t*e interlaminar stren,t* is matri3 dominated 4i.e., i2 t*e matri3 is #ea7, pl0 delamination can occur6. (o.en 2i"er composites are similar to ordinar0 clot* used in t*e te3tile industr0. )*e #o.en 2i"er ma0 "e 1-5 42i"ers inter#o.en in

A07 - Introduction to Composite Materials

1 directions6 or 3-5 42i"ers inter#o.en in 3 directions6. (o.en 2i"er composites do not ,enerall0 *a.e distinct laminae and are not nearl0 as suscepti"le to delamination8 *o#e.er, stren,t* and sti22ness are sacri2iced due to t*e 2act t*at t*e 2i"ers are not as strai,*t 4"ecause o2 t*e #ea.in,6 as in t*e continuous 2i"er laminate. C*opped 2i"er composites *a.e 2i"ers t*at are relati.el0 s*ort and *a.e a random orientation and distri"ution o2 t*e 2i"ers. C*opped 2i"er composites ,enerall0 *a.e mec*anical properties t*at are considera"le poorer t*an t*ose o2 continuous 2i"er composites. Ho#e.er t*e0 are c*eaper to manu2acture and are used in *i,*.olume applications. H0"rid composites ,enerall0 consist o2 mi3ed c*opped and continuous 2i"ers8 or mi3ed 2i"er t0pes suc* as ,lass>,rap*ite.

A07 - Introduction to Composite Materials

'and#ic* composites are also common. )*e0 consist o2 *i,* stren,t* composite 2acin, s*eets 4#*ic* ma0 "e an0 o2 t*e 2our 2i"er composites discussed a"o.e6 "onded to a li,*t#ei,*t 2oam or *one0com" core 42rom !i"son6.

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'and#ic* structures *a.e e3tremel0 *i,* 2le3ural sti22ness-to#ei,*t ratios and are #idel0 used in aerospace structures. )*e desi,n 2le3i"ilit0 o22ered "0 t*ese and ot*er composite con2i,urations is o".iousl0 ?uite attracti.e to desi,ners, and t*e potential no# e3ist to desi,n not onl0 t*e structure, "ut also t*e structural material itsel2. Almost all o2 t*e 2i"er-rein2orced composite t0pes discussed a"o.e can "e utili:ed in comple3 cur.ed ,eometries alt*ou,* t*e manu2acturin, process ma0 "e muc* more costl0 and di22icult. or e3ample, #ound 2i"er-rein2orced pressure .essels are common and are manu2actured "0 #indin, eit*er indi.idual 2i"er 2ilaments on a mandrel 4*a.in, t*e s*ape o2 t*e .essel6 or indi.idual plies are #ound on t*e mandrel. Cur.ed composite material panels on aircra2t #in,s, 2usela,e and nacelles are common. All o2 t*e composite t0pes *a.e .arious manu2acturin, processes re?uired to "ond indi.idual plies. Common ,lass-epo30

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composites must "e cured usin, a *i,* temperature and .acuum 4or pressure6 process desi,ned not onl0 to "ond indi.idual plies "ut also to minimi:e residual laminae and interlaminar stresses. Fiber Materials !lass 2i"ers consist primaril0 o2 silica 4silicon dio3ide6 and metallic-o3ide-modi20in, elements are ,enerall0 produced "0 mec*anical dra#in, o2 molten ,lass t*rou,* a small ori2ice. E,lass accounts 2or most o2 t*e ,lass 2i"er production and is t*e most #idel0 used rein2orcement 2or composites. )*e second most popular ,lass 2i"er, '-,lass, *as rou,*l0 30 percent ,reater tensile stren,t* and 10 percent ,reater modulus o2 elasticit0 t*an E-,lass "ut is not as #idel0 used "ecause o2 its *i,*er cost. !rap*ite or car"on 2i"ers are t*e most #idel0 used ad.anced 2i"er, and ,rap*ite>epo30 or car"on>epo30 composites are no# used routinel0 in aerospace structures. )*e actual 2i"ers are usuall0 produced "0 su"9ectin, or,anic precursor 2i"ers suc* as

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pol0acr0lonitrile 4+A@6 or ra0on to a se?uence o2 *eat treatments, so t*at t*e precursor is con.erted to car"on "0 p0rol0sis. !rap*ite 2i"ers are t0picall0 su"9ected to *i,*er *eat treatments t*an are car"on 2i"ers. Car"on 2i"ers are t0picall0 $0-$&A car"on, #*ereas ,rap*ite 2i"ers are at least $$A car"on. Aramid pol0mer 2i"ers, produced primaril0 "0 E.I. du+ont de@emours B Compan0 under t*e tradename <Ce.lar,< #ere ori,inall0 de.eloped 2or use in radial tires. )*e densit0 o2 Ce.lar is a"out *al2 t*at o2 ,lass and its speci2ic stren,t* is amon, t*e *i,*est o2 currentl0 a.aila"le 2i"ers. Ce.lar also *as e3cellent tou,*ness, ductilit0, and impact resistance8 unli7e "rittle ,lass or ,rap*ite 2i"ers. Doron 2i"ers are actuall0 composites consistin, o2 a "oron coatin, on a su"strate o2 tun,sten or car"on. )*e diameter o2 "oron 2i"ers is amon, t*e lar,est o2 all t*e ad.anced 2i"ers, t0picall0 0.0010.00- in. Doron 2i"ers *a.e muc* *i,*er stren,t* and sti22ness

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t*an ,rap*ite, "ut t*e0 also *a.e *i,*er densit0. Doron>epo30 and "oron>aluminum composites are #idel0 used in aerospace structures, "ut *i,* cost pre.ents more #idespread use. 'ilicon car"ide 4'iC6 2i"ers are used primaril0 in *i,*-temperature metal and ceramic matri3 composites "ecause o2 t*eir e3cellent o3idation resistance and *i,*-temperature stren,t* retention. 'iC #*is7er-rein2orced metals are increasin,l0 "ein, used as alternati.e to un-rein2orced metals and continuous 2i"er-rein2orced metals. 'iC #*is7ers are ?uite small, t0picall0 --10 in. diameter and a"out 0.0011 in. lon, so t*at standard metal-2ormin, processes suc* as e3trusion, rollin, and 2or,in, can "e easil0 used. )*e list o2 2i"ers ,oes on E On t*e 2ollo#in, pa,es are a6 'elected properties o2 2i"ers and "ul7 metals, "6 'peci2ic stren,t* .s. speci2ic modulus 2or .arious 2i"ers and c6 'peci2ic stren,t* .s. speci2ic modulus 4sti22ness6 2or .arious composites 42rom !i"son6. 'peci2ic .alue is t*e .alue o2 t*e propert0 di.ided "0 its densit0.

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A07 - Introduction to Composite Materials

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A07 - Introduction to Composite Materials

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A07 - Introduction to Composite Materials

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Matrix and Filler Materials +ol0mers, metals and ceramics are all used as matri3 materials in composites. )*e matri3 *olds t*e 2i"ers to,et*er in a structural unit, protects t*em 2rom e3ternal dama,e, trans2ers and distri"utes t*e applied loads to t*e 2i"ers, and in man0 cases, contri"utes some needed propert0 suc* as ductilit0, tou,*ness, or electrical insulation. Decause t*e matri3 must trans2er load to t*e 2i"ers, a stron, inter2ace "ond "et#een t*e 2i"er and matri3 is e3tremel0 important8 eit*er t*rou,* a mec*anical or c*emical "ond "et#een 2i"ers and matri3. i"ers and matri3 must o".iousl0 "e c*emicall0 compati"le to pre.ent undesira"le reactions at t*e inter2ace8 t*is is especiall0 important at *i,* temperature #*ere c*emical reactions can "e accelerated.

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'er.ice temperature is ?uite o2ten a controllin, 2actor in consideration o2 a matri3 material. Fisted in order o2 increasin, temperature capa"ilit0, #e *a.e/ +ol0mers are t*e most #idel0 used matri3 materials. )*e0 ma0 "e eit*er t*ermosets 4e.,., epo30, pol0ester, p*enolics6 or t*ermoplastics 4e.,., pol0imide 4+I6, pol0et*eret*er7etone 4+EEC6, pol0p*en0lene sul2ide 4++'66. =pon curin,, t*ermosets 2orm a *i,*l0 cross-lin7ed, t*ree-dimensional molecular net#or7 #*ic* does not melt at *i,* temperature. )*ermoplastics, *o#e.er, are "ased on pol0mer c*ains t*at do not cross-lin7. As a result, t*ermoplastics #ill so2ten and melt at *i,* temperature, t*en *arden a,ain upon coolin,. Epo3ies and pol0esters are also #idel0 used. Hi,* ,rade epo3ies are t0picall0 cured at a"out 3&0 and are ,enerall0 not used at temperatures a"out 300 . )*e ad.anced t*ermoplastics 4+EEC, +I and ++'6 *a.e meltin, temperatures in t*e ran,e o2 ;00-700 .

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or *i,*er temperatures, metal, ceramic or car"on matri3 materials are re?uired. Fi,*t#ei,*t metals suc* as aluminum, titanium and ma,nesium and t*eir allo0s suc* titanium aluminide and nic7el aluminide ma0 "e used as matri3 materials. or some o2 t*ese, operatin, temperature can "e e3tended to a"out 1,1&0 . Ad.anta,es o2 metal matrices include *i,*er stren,t*, sti22ness and ductilit0 4compared to pol0mers6 "ut at t*e e3pense o2 *i,*er densit0. Ceramic matri3 materials suc* as silicon car"ide and silicon nitride can "e use at temperatures up to 3,000 . Hoe.er, ceramics *a.e poor tensile stren,t* are are ?uite "rittle. Car"on 2i"er>car"on matri3 composites can "e used at temperatures approac*in, &,000 , "ut t*e cost is suc* t*at t*e0 are onl0 used in a 2e# critical aerospace applications.

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iller materials are o2ten used as a t*ird component o2 a composite, and are t0picall0 mi3ed #it* t*e matri3 material durin, 2a"rication. illers do not t0picall0 en*ance mec*anical properties "ut are used to alter or impro.e some ot*er c*aracteristic o2 t*e composite. E3amples include/ *ollo# ,lass microsp*eres are used to reduce #ei,*t, cla0 or mica particles are used to reduce cost, car"on "lac7 particles are used 2or protection a,ainst ultra.iolet radiation, and alumina tri*0drate is used 2or 2lame and smo7e suppression.