Composite Materials

Composite
A material system composed of two or
more physically distinct phases whose
combination
produces
aggregate
properties that are different from those
of its constituents.
Design goal: obtain a more desirable
combination of properties (principle of
combined action)
e.g., low density and high strength
2

 Wood is a good example of a natural

composite, combination of cellulose fiber
and lignin. The cellulose fiber provides
strength and the lignin is the "glue" that
bonds and stabilizes the fiber.

heavy

Lower Tm

A composite material consists of two phases:

Primary (continuous)
Forms the matrix which is usually more ductile and
less hard phase
Any of three basic material types: polymers,
metals, or ceramics
Shares the load with the secondary phase

Secondary (discontinuous)
Referred to as the dispersed/embedded phase or
called the reinforcing agent
Serves to strengthen the composite (fibers,
particles, etc.)
Can be one of the three basic materials or an
element such as carbon or boron

Classification of composite materials

(based on matrix material)
Metal Matrix Composites (MMCs)
Include mixtures of ceramics and metals, such as
cemented carbides and other cermets, as well as
aluminum or magnesium reinforced by strong, high
stiffness fibers
Ceramic Matrix Composites (CMCs)
Least common composite matrix. Aluminum oxide
and silicon carbide are materials that can be
imbedded with fibers for improved properties,
especially in high temperature applications
Polymer Matrix Composites (PMCs)
Thermosetting resins are the most widely used
polymers in PMCs. Epoxy and polyester are
commonly mixed with fiber reinforcement

Classification of composite materials

(based on reinforcing material structure)

Particulate Composites

Fibrous Composites

Laminate Composites

Particulate Composites
Consist of a matrix reinforced with a dispersed phase
in form of particles.
Very small particles (< 0.25 micron in diameter) finely
distributed in the matrix impede movement of
dislocations and deformation of the material.
Large dispersed phase particles have low strengthening
effect but they are capable to share load applied to the
material, resulting in increase of stiffness and decrease
of ductility.

Particulate Composites
Hard particles dispersed in a softer matrix increase wear
and abrasion resistance.
Soft dispersed particles in a harder matrix improve
machinability (lead particles in steel or copper matrix) and
reduce coefficient of friction (tin in aluminum matrix or
lead in copper matrix).
Composites with high electrical conductivity matrices
(copper, silver) and with refractory dispersed phase
(tungsten, molybdenum) work in high temperature
electrical applications.

Fibrous Composites
Dispersed phase in form of fibers improves strength,
stiffness and fracture toughness of the material,
impeding crack growth in the directions normal to the
fiber.

Effect of the strength increase becomes much more

significant when the fibers are arranged in a particular
direction (preferred orientation) and a stress is applied
along the same direction.

-Maximum strength is obtained when long fibers are

oriented parallel to the applied load

Fibrous Composites
Short-fiber reinforced composites, consisting of a
matrix reinforced with a dispersed phase in form
discontinuous fibers (length < 100*diameter), has a
limited ability to share load.
Load, applied to a long-fiber reinforced composite, is
carried mostly by the dispersed phase - fibers. Matrix
in such materials serves only as a binder of the fibers
keeping them in a desired shape and protecting them
from mechanical or chemical damages.

The strength of the composite increases as the fiber

length increases (this is a chopped E-glass-epoxy
composite).

Laminate Composites

Consist of layers with different anisotropic orientations or

of a matrix reinforced with a dispersed phase in form of
sheets.
They provide increased mechanical strength in two
directions and only in one direction, perpendicular to the
preferred orientations of the fibers or sheet, mechanical
properties of the material are low.

Polymer Matrix Composites

A polymer (resin) matrix combined with a fibrous
reinforcing dispersed phase.
Very popular due to their low cost and simple
fabrication methods.
Non-reinforced polymers cant be used as structural
materials due to low mechanical properties. Tensile
strength of one of the strongest polymers - epoxy resin
is 140 MPa. Low impact resistance is another
drawback.

Merits of PMC

High tensile strength

High stiffness
High fracture toughness
Good abrasion resistance
Good puncture resistance
Good corrosion resistance
Low cost.

Demerits of PMC
Low thermal resistance
High coefficient of thermal expansion.

PMC Applications

secondary load-bearing aerospace structures,

boat bodies, canoes, kayaks,
automotive parts,
radio controlled vehicles,
sport goods (golf clubs, skis, tennis racquets, fishing
rods),
bullet-proof vests and other armor parts,
brake and clutch linings.

According to the reinforcement material the following

groups of Polymer Matrix Composites (PMC) are used:
Fiberglasses Glass Fiber Reinforced Polymers
Carbon Fiber Reinforced Polymer Composites
Kevlar (aramid) Fiber Reinforced Polymers

Glass Fiber Reinforced Plastic

(Fiberglass)
The reinforcing dispersed phase may be in form of
either continuous or discontinuous glass fibers.
Glass fiber dia range is 5 to 25 micrometer.
Concentration of glass fibers in fiberglass is normally
about 40% - 70%.
There are a variety of types of glass, they are all
compounds of silica with a variety of metallic oxides.
The most popular matrix materials are Thermosets
such as unsaturated polyesters (UP), epoxies (EP) and
Thermoplastics
such
as
nylon
(polyamide),
polycarbonate (PC), PS, PVC.

Stress-strain behavior of different polymer matrices

Thermosetting polymers

Thermoplastic polymers
80

90
Polysulfon

70

80
70

50
40
Polyamid
Polyethylene

30

Stress (Mpa)

Stress (Mpa)

60

40
30

10

10

0
200
300
Strian(% )

400

500

Phenolic

50

20

100

Epoxy

60

20

Polyester

2
3
Strian(%)

Designation:

Property or Characteristic:

E, electrical

low electrical conductivity

S, strength

high strength

C, chemical

high chemical durability

M, modulus

high stiffness

A, alkali

high alkali or soda lime glass

D, dielectric

low dielectric constant

The most commonly used glass is E-glass, which is

the most popular because of its low cost

Fiberglasses are characterized by the following properties:

High strength-to-weight ratio;
High modulus of elasticity-to-weight ratio;
Good corrosion resistance;
Good insulating properties;
Low thermal resistance (as compared to metals and
ceramics).
Fiberglass materials are used for manufacturing: boat
hulls and marine structures, automobile and truck body
panels, pressure vessels, aircraft wings and fuselage
sections, housings for radar systems, swimming pools,
welding helmets, roofs, pipes.

Kevlar Fiber Reinforced Polymers

Kevlar is the trade name (registered by DuPont Co.) of
aramid (poly-para-phenylene terephthalamide) fibers.
Kevlar fibers possess the following properties:
High tensile strength (five times stronger per weight unit
than steel);
High modulus of elasticity;
Very low elongation up to breaking point;
Low weight; High chemical inertness;
Very low coefficient of thermal expansion;
High Fracture Toughness (impact resistance);
Textile processibility; Flame resistance.

 The disadvantages of Kevlar are: ability to absorb

moisture, difficulties in cutting, low compressive
strength.
Kevlar 29 high strength (3600 MPa), low density (1440
kg/m) fibers used for manufacturing bullet-proof vests,
composite armor reinforcement, helmets, ropes, cables,
asbestos replacing parts.
Kevlar 49 high modulus (131 GPa), high strength
(3800 MPa), low density (90 lb/ft/1440 kg/m) fibers
used in aerospace, automotive and marine applications.
Thermosets such as Epoxies (EP), Vinylester and
Phenolics (PF) are used as matrix materials

Carbon Fiber Reinforced Polymers

The reinforcing dispersed phase may be in form of either
continuous or discontinuous carbon fibers of diameter
about 0.0004 commonly woven into a cloth.
Carbon fibers are very expensive but they possess the
highest specific mechanical properties: modulus of
elasticity and strength.
Carbon fibers are used for reinforcing polymer matrix due
to the following properties:
Very high modulus of elasticity exceeding that of steel;
High tensile strength, which may reach 7 GPa
Low density: 1800 kg/m
High chemical inertness

 The most popular matrix materials for manufacturing

Carbon Fiber Reinforced Polymers (CFRP) are
thermosets such as epoxy, polyester and thermoplastics
such as nylon (polyamide).
CFRP are characterized by the following properties:
Light weight; High strength-to-weight ratio;
Very High modulus of elasticity-to-weight ratio;
High Fatigue strength; Good corrosion resistance;
Very low coefficient of thermal expansion;
Low impact resistance; High electric conductivity;
High cost.

Carbon Fiber Reinforced Polymers (CFRP) are used for

manufacturing:
automotive marine and aerospace parts,
sport goods (golf clubs, skis, tennis racquets, fishing
rods),
bicycle frames.

COMMERCIALLY AVAILABLE FORMS OF

REINFORCEMENT

Above Left: Roving

Above Right: Filaments
Right: Close up of a roving

Random mat and woven fabric (glass fibers)

Carbon fiber woven fabric

Metal Matrix Composites

The metal matrix composites offer higher modulus of
elasticity, ductility, and resistance to elevated temperature
than polymer matrix composites. But, they are heavier and
more difficult to process.

CEMENTED CARBIDES (CERMETS)

Cemented carbides are an example of

regular particulate MMCs
Carbides such as WC (tungsten-carbide)
are used for cutting tool inserts but this
hard ceramic is very brittle so it cracks
or chips under impact loads, to remedy
this cobalt is used as a matrix

Cutting tool inserts, a milling tool

and a lathe tool

Ceramic Matrix Composites

Ceramic matrix composites (CMC) are used in
applications where resistance to high temperature and
corrosive environment is desired. CMCs are strong and
stiff but they lack toughness (ductility).
Matrix materials are usually silicon carbide, silicon nitride
and aluminum oxide, and mullite (compound of aluminum,
silicon & oxygen). They retain their strength up to 3000 oF.
Fiber materials used commonly are carbon and aluminum
oxide.
Applications are in jet and automobile engines, deep-sea
mining, cutting tools, dies and pressure vessels.

Advantages of Composites
Higher Specific Strength (strength-toweight ratio)
Composites have a higher specific strength
than many other materials. A distinct
advantage of composites over other materials
is the ability to use many combinations of
resins and reinforcements, and therefore
custom tailor the mechanical and physical
properties of a structure.

Design flexibility
Composites have an advantage over other
materials because they can be molded into
complex shapes at relatively low cost. This gives
designers the freedom to create any shape or
configuration. Boats are a good example of the
success of composites.
Corrosion Resistance
Composites provide long-term resistance to
severe
chemical
and
temperature
environments. Composites are the material of
choice for outdoor exposure, chemical handling
applications, and severe environment service.

Low Relative Investment

One reason the composites industry has been
successful is because of the low relative
investment
in
setting-up
a
composites
manufacturing facility.

Durability
Composite products and structures have an
exceedingly long life span. Coupled with low
maintenance requirements, the longevity of
composites is a benefit in critical applications.

Disadvantages of Composites
Composites are highly anisotropic
The strength in composites vary as the direction
along which we measure changes (most
engineering structural materials are isotropic).
As a result, all other properties such as,
stiffness, thermal expansion, thermal and
electrical conductivity and creep resistance are
also anisotropic. The relationship between stress
and strain (force and deformation) is much
more complicated than in isotropic materials.

Composites are heterogeneous

properties in composites vary from point to
point in the material. Most engineering
structural materials are homogeneous.
composites materials are difficult to inspect
with conventional ultrasonic, eddy current
and
visual
NDT
methods
such
as
radiography.

Application of Composites in Aircraft Industry

20% more fuel efficiency and

35,000 lbs. lighter