Composite Materials

Lesson on

CHEM1013

Advanced Engineering Materials

DEPARTMENT OF CHEMISTRY K L E F University

Composite materials Introduction

Definition: Any combination of two or more different materials at the macroscopic level. OR Two inherently different materials that when combined together produce a material with properties that exceed the constituent materials.

Reinforcement phase (e.g., Fibers) Binder phase (e.g., matrix phase resin)

Common examples Wood , Packing paper , impregnated with wax. Rain coat made of cloth impregnated with waterproof material and concrete.

Composite materials Advantages

Advantages

High strength and stiffness Low weight Specific gravity They are tough having good thermal shock resistance. Thermal expansion , conductivity as well as electrical conductivity are low. In many composites corrosion and oxidation resistance are much better than metals. Large parts can often be fabricated more easily and cheaply than from other metals.

Applications

Straw in clay construction by Egyptians Aerospace industry Sporting goods Automotive Construction Land transportation Marine industry

Types of Composites
Matrix phase/Reinforc ement Phase
Metal

Metal

Ceramic

Polymer

Powder metallurgy parts combining immiscible metals Cermets, TiC, TiCN Cemented carbides used in tools Fiber-reinforced metals

Cermets (ceramicmetal composite)

Brake pads

Ceramic

SiC reinforced Al2O3 Tool materials

Fiberglass

Polymer
Elemental (Carbon, Boron, etc.)
Fiber reinforced metals Auto parts aerospace

Kevlar fibers in an epoxy matrix

Rubber with carbon (tires) Boron, Carbon reinforced plastics

MMCs
Metal Matrix Composites

CMCs
Ceramic Matrix Comps.

PMCs
Polymer Matrix Comps

Types of Composite Materials

There are five basic types of composite materials: Fiber, particle, flake, laminar or layered and filled composites.

A. Fiber Composites
In fiber composites, the fibers reinforce along the line of their length. Reinforcement may be mainly 1-D, 2-D or 3-D. Figure shows the three basic types of fiber orientation. 1-D gives maximum strength in one direction. 2-D gives strength in two directions.
Isotropic gives strength equally in all directions.

Composite strength depends on following factors: Inherent fiber strength, Fiber length, Number of flaws Fiber shape The bonding of the fiber (equally stress distribution) Voids Moisture (coupling agents)

B. Particle Composites
Particles usually reinforce a composite equally in all directions (called isotropic). Plastics, cermets and metals are examples of particles. Particles used to strengthen a matrix do not do so in the same way as fibers. For one thing, particles are not directional like fibers. Spread at random through out a matrix, particles tend to reinforce in all directions equally. Cermets (1) OxideBased cermets (e.g. Combination of Al2O3 with Cr) (2) CarbideBased Cermets (e.g. Tungstencarbide, titaniumcarbide) Metalplastic particle composites (e.g. Aluminum, iron & steel, copper particles) Metalinmetal Particle Composites and Dispersion Hardened Alloys (e.g. Ceramicoxide particles)

C. Flake Composites - 1
Flakes, because of their shape, usually reinforce in 2-D. Two common flake materials are glass and mica. (Also aluminum is used as metal flakes)

C. Flake Composites -2
A flake composite consists of thin, flat flakes held together by a binder or placed in a matrix. Almost all flake composite matrixes are plastic resins. The most important flake materials are:

1. Aluminum 2. Mica 3. Glass

C. Flake Composites -3
Basically, flakes will provide: Uniform mechanical properties in the plane of the flakes Higher strength Higher flexural modulus Higher dielectric strength and heat resistance Better resistance to penetration by liquids and vapor Lower cost

D. Laminar Composites - 1
Laminar composites involve two or more layers of the same or different materials. The layers can be arranged in different directions to give strength where needed. Speedboat hulls are among the very many products of this kind.

D. Laminar Composites - 2
Like all composites laminar composites aim at combining constituents to produce properties that neither constituent alone would have. In laminar composites outer metal is not called a matrix but a face. The inner metal, even if stronger, is not called a reinforcement. It is called a base.

D. Laminar Composites - 3
We can divide laminar composites into three basic types: Unreinforcedlayer composites (1) AllMetal (a) Plated and coated metals (electrogalvanized steel steel plated with zinc) (b) Clad metals (aluminumclad, copperclad) (c) Multilayer metal laminates (tungsten, beryllium) (2) MetalNonmetal (metal with plastic, rubber, etc.) (3) Nonmetal (glassplastic laminates, etc.) Reinforcedlayer composites (laminae and laminates) Combined composites (reinforcedplastic laminates well bonded with steel, aluminum, copper, rubber, gold, etc.)

D. Laminar Composites - 4
A lamina (laminae) is any arrangement of unidirectional or woven fibers in a matrix. Usually this arrangement is flat, although it may be curved, as in a shell. A laminate is a stack of lamina arranged with their main reinforcement in at least two different directions.

E. Filled Composites
There are two types of filled composites. In one, filler materials are added to a normal composite result in strengthening the composite and reducing weight. The second type of filled composite consists of a skeletal 3-D matrix holding a second material. The most widely used composites of this kind are sandwich structures and honeycombs.

F. Combined Composites
It is possible to combine several different materials into a single composite. It is also possible to combine several different composites into a single product. A good example is a modern ski. (combination of wood as natural fiber, and layers as laminar composites)

Fibre-Reinforced Plastic (FRP)

Polymeric substance + Solid filler = Reinforced Plastic Filler acts as reinforcing material, while the polymer links the filler particles. Using different matrix resins and reinforcing fibers and a variety of processing techniques, a multitude of products are manufactures. Reinforcing fibers may be natural or synthetic organic or inorganic polymers such as jute, asbestos, nylon, polyester, aramides (Kevlar), glass, carbon, boron, aluminium, SiC. The fiber and the resin are combined in a suitable manner to get desired properties.

Fibre-Reinforced Plastic (FRP) contd.

Properties: 1. Light weight & cost effective 2. High modulus & strong. 3. High impact strength 4. High creep & load 5. High service temperature 6. Not easily corroded 7. High melting points 8. Good dimensional stability 9. Good thermal & shock resistance 10. Good processability

Fibre-Reinforced Plastic (FRP) contd.

Applications: Land transportation Construction Corrosion resistance equipment Marine equipment Electrical & Electronics industry Various appliances & Business articles Used in aircraft, aerospace & military goods, and Automobiles. For example,

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Carbon Fiber-Reinforced Plastic (CFRP)

Polymeric substance + Carbon fiber = Reinforced Plastic Carbon fibers can be combined usefully with a variety of plastic resins & polymers to yield composites of exceptionally high specific stiffness and strength. Matrix materials; many thermosetting resins & thermo platics are suitable for combination with carbon fibers. Thermosetting resins such as epoxides, epoxies, poly esters, phenolics, vinyl esters are used. Thermoplastic resins such as polyamides, poly carbonates, polysulphones, etc are used.

Carbon Fiber-Reinforced Plastic (CFRP) contd

Properties: High specific stiffness & strength High specific modulus Good mechanical strength Creep resistance Electrically conductive along with filament axis Low thermal expansion & good chemical resistance.

Carbon Fiber-Reinforced Plastic (CFRP) contd

Applications: In structural components such as air frame structures, space vehicles and satellites. High speed reciprocating parts for industrial machinery and also for very high temperature machinery. Used in Sports equipment

Glass Fiber-Reinforced Plastic (GFRP) contd

Polymeric substance + glass fiber = Reinforced Plastic Matrix materials are polypropylene, polyamide, polysulphones, polyimides, polyester ketones, polyester and epoxy resin. Properties: It has improved stiffness & strength than other materials. Decrease shrinkage Reduce thermal expansion Good dimensional stability at high temperature.

Glass Fiber-Reinforced Plastic (GFRP) contd

Applications:
Bridges & airplane wings Automobile industry Boat hulls Circuit boards & corrosion resistance equipment

Current Status of FRP Utility Structures

FRP utility structures include poles, crossarms, stand-offs and now conductor reinforcement Composite, or fiberglass poles, were installed in West Oahu in 1962 and were only recently taken out of service Composite lighting poles have an extensive history of use dating back more than 40 years The use of FRP utility structures throughout the U.S. is widespread and still growing The use of FRP utility structures in Canada is growing Some larger installations...
8,000+ FRP poles at large California utilities starting 1995 1,500+ FRP poles at Rural Coops since 2000 300+ FRP poles at Northwest Territories since 2003 100,000+ FRP crossarms across virtually every state

Installations

Residential Backyard Installations

Remote Installations

Deadend Crossarms

Joint Use with Transformers