Composites

TECH 3421

What are Composites?

Two or more distinct materials that keep their own
properties.
The goal is to achieve a synergistic relationship between
the different components.
The category of composites can include

Plated parts

Clad parts

Coated metals

Reinforced concrete
Generally, the term refers to a material with a matrix and a
reinforcement

Matrix and Reinforcement

Matrix functions (word means supporting or
enclosing structure)
Acts as a binder
Controls physical shape and dimensions
Transfers the load to the reinforcement
Protects the reinforcement
btw... the first use of the word matrix to refer to "cyberspace" was in 1976 R.
Holmes Dr. Who: Deadly Assassin (BBC TV script) 50
Engin. How can you intercept thought patterns within the matrix itself? The
Doctor: By going in there. By joining it. (OED)

Why use Composites

http://www-materials.eng.cam.ac.uk/mpsite/interactive_charts/strength-density/generics.jpg

Matrix and Reinforcement

The reinforcement functions:
To enhance mechanical properties
Usually the primary load bearing element
Can be fibers or particles (long, oriented
fibers offer the best strength)
Physical properties of the material are affected
by the reinforcement...
Density
Thermal expansion & Conductivity
Vibration Dampening

Matrix and Reinforcement Materials

Polymers
Metals
Ceramics
Carbon

http://commons.wikimedia.org/wiki/File:Carbon_fiber.jpg

About Carbon Fiber...

Extremely strong. High stiffness, high
tensile strength, low weight, high chemical
resistance, high temperature tolerance.
Production starts with a polymer
precursor (usually rayon, polyacrylonitrile
[PAN]) which is heated to drive off noncarbon atoms. Oriented carbon crystal
strands form and bond side to side.
Fiber is etched and sized (coated)
Fiber is then wound and/or woven

Carbon Fiber

Natural Composites
Wood
Lignin
Cellulose

http://commons.wikimedia.org/wiki/File:Abies_concolor_tangential.jpg

Lignin as a CF Precursor

Natural Fiber Reinforcement

Sometimes natural fibers are used as
reinforcement in a thermoplastic matrix (see
Micarta).
Examples include:
Coconut fiber (coir) [used in 2012 Ford Focus]

Cotton fiber
Sisal
Kenaf
Hemp
Jute
http://en.wikipedia.org/wiki/Jute

Common Matrix Materials

The most common matrix materials are
thermosetting polymers.
Polyesters (low cost, but low strength) most
popular
Epoxies
Bismaleimides
Phenolics
Polyimides

Common Reinforcement Materials

E-Glass (almumino-borosilicate glass)
Aramid (example is Kevlar)
Carbon (or Graphite)
Can be in the form of:
Strand (twisted bundle of filaments)
Tow (untwisted bundle)
Filaments
Fabrics
Pre-impregnated tapes
Pre-forms

Composites Manufacturing
The most common methods of manufacturing
composites are:
Manual lay-up
Automated lay-up
Filament winding
Pultrusion
Resin transfer molding

General Lay-Up Procedure

Coating mold with release agent
Coating mold with gel-coat
Laying up fibers into mold
Impregnating with matrix material
Rolling to remove trapped air
This process is repeated to layer the fibers
Curing (often in a vacuum bag)

Manual Lay-Up
Cutting and impregnating the fibers manually.

Automated Fiber Placement

CNC AFP machines
Can lay prepreg fibers and tapes
Tape machines require shape to be relatively
flat to avoid wrinkles and overlaps.
Fiber machines can lay-up more complicated
geometry

Braided Lay-up
Applies technology used for hose reinforcement
braiding.

Alt. Video

Filament Winding
Wrapping a narrow fiber tow around a mandrel
Can be
Helical
Hoop
Mandrel either collapses, is left in place, or is
dissolved away.

Spray-Up
Resin and fibers are sprayed together. Gun
chops continuous reinforcement into small
strands.

Curing
Can be done at room temperature
Sometimes with heated air assist
Ovens
Heated platen presses
Autoclaves
Curing often involves using vacuum bag or
pressure bag (internal bladder) molding

Pultrusion
Produces long, straight shapes of a given
profile (much like extruded shapes)

Resin Transfer Molding (RTM)

Used to create large, complex items for high
production, such as shower enclosures,
cabinets, aircraft parts, automotive
components.
Mold halves are loaded with reinforcement
material.
Resin is pumped in and cures.

Vacuum Resin Infusion

Reinforcement is placed in one or two-sided
mold. Vacuum pulls resin into the mold.

Composites Fabrication and

Assembly
Composites can be machined, Drilled and
sawn.
Tooling must be sharp and resistant to
abrasion.
Commonly, tools are carbide or diamond
tipped.
Delamination is a primary problem when
machining or drilling composites.
Composites are often bonded with adhesive
and/or mechanical fasteners.

Recommended
Machining of Composites Materials
Composites in Aviation
NASA TP AFP Cryogenic
Felt Bicycle Manufacturing
Modern Marvels - Carbon