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and which are insoluble in each other. The history of composite materials dates back to early 20th century. In 1940, fiber glass was first used to reinforce epoxy. Applications:
Aerospace industry Sporting Goods Industry Automotive Industry Home Appliance Industry
Composites
Particle-reinforced
Fiber-reinforced
Structural
Largeparticle
Dispersionstrengthened
Continuous (aligned)
Discontinuous (short)
Laminates
Sandwich panels
Aligned
Randomly oriented
It is often composed of fibres embedded in a matrix. Matrix is in liquid or powder form and is combined with reinforcing fibres in a mould and high heat and pressure is applied until fusion occur Matrix can be metals, ceramics or plastics Fibres are excellent in tension but cant handle compression well. So they are glued together within matrix thus improving its property.
It might also be a laminate of different materials formed like sandwich It consists of two layers of fibres held apart by light weight core(foam or honey comb style) This provide stiffness
Air bus is using carbon fibre in wing Advantage: strength, stiffness, fatigue resistant, corrosion resistant and weight benefits Disadvantage: lack of historical data on long term effect of uv and weathering Little long term performance data
Rubber pads reinforced with steel plates Rubber provide flexibility in response to movement and absorb stress and strain while being resilient Steel adds strength and stabilise structure. Also increase its compression resistance but will allow it to flex
Exceptionally low density High strength Corrosion resistance Ability to fabricate complex shapes Excellent fraction and fatigue resistance Low thermal expansion
High cost of raw materials Few mass production processes available Properties of laminated composites: - low through-thickness strength - low interlaminar shear strength No off the shelf properties - performance depends on quality of manufacture
Particle-reinforced
Fiber-reinforced
Structural
Particle-reinforced
Fiber-reinforced
Structural
Concrete - hard particles (gravel) + cement (ceramic/ceramic composite). Properties determined by particle size distribution, quantity and matrix formulation Additives and fillers in polymers: carbon black (conductivity, wear/heat resistance) aluminium trihydride (fire retardancy) glass or polymer microspheres (density reduction) chalk (cost reduction) Cutting tool materials and abrasives (alumina, SiC, BN bonded by glass or polymer matrix; diamond/metal matrix) Electrical contacts (silver/tungsten for conductivity and wear resistance) Cast aluminium with SiC particles
Particle-reinforced
Fiber-reinforced
Structural
Fiber Materials
Whiskers - Thin single crystals - large length to diameter ratio graphite, SiN, SiC high crystal perfection extremely strong, strongest known very expensive Fibers polycrystalline or amorphous generally polymers or ceramics Ex: Al2O3 , Aramid, E-glass, Boron, UHMWPE Wires Metal steel, Mo, W
Particle-reinforced
Fiber-reinforced
Structural
Stacked and bonded fiber-reinforced sheets -- stacking sequence: e.g., 0/90 or 0/45/90
-- benefit: balanced, in-plane stiffness
Sandwich panels
-- low density, honeycomb core -- benefit: light weight, large bending stiffness
face sheet adhesive layer honeycomb
Adapted from Fig. 16.18, Callister 7e. (Fig. 16.18 is from Engineered Materials Handbook, Vol. 1, Composites, ASM International, Materials Park, OH, 1987.) Adapted from Fig. 16.16, Callister 7e.
1. Consist of two or more physically distinct and mechanically separable parts. 2. Constituents can be combined in a controlled way to achieve optimum properties. 3. Properties are superior, and possibly unique, compared those of the individual components
GLASS + POLYESTER = composite (strength) (chemical resistance) (strength and chemical resistance)
Unique properties:
GLASS (brittle) + POLYESTER (brittle) = GRP (tough!)
Aerospace, defence, F1 Highly stressed Glass, carbon, aramid fibres Honeycomb cores Epoxy, bismaleimide Prepregs Vacuum bag/oven/autoclave
Marine, building Lightly stressed Glass (random and woven) Foam cores Polyester, vinylester Wet resins Hand lay up, room temperature cure
Aesthetic appeal Ability to mould complex shapes Various surface finishes available
Lightweight
Durability / Corrosion resistance Parts integration
Cost effectiveness
Electrical properties
Roofs / canopies Complete buildings Cladding panels Masts & towers Domes
Unusual architectural features / structures Radomes Permanent or temporary formwork Strengthening / repair of conventional structures
Tanks, covers, pipes, ducts etc
Photo - Carrillion
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Huge potential for polymer composites in civil engineering/construction applications. Large structures need particular types of manufacturing process. Raw materials are expensive need low-cost manufacture and justification for composites. Building industry is conservative resistance to new materials. Design codes for composite structures available but not widely adopted.
David Kendall, CETEC (2001)
Particulate Methods: Sintering Fiber reinforced: Several Structural: Usually Hand lay-up and atmospheric curing or vacuum curing