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Andrew Nydam
Slides from Ken Youssefi
Mary P. Shafer
Fabric Development, Inc. Quakertown, PA 18951
Reinforcement
Tensile Properties
Stiffness
Impact Resistance
Composites
Composites are combinations of two materials in which one of the material is called
the reinforcing phase, is in the form of fibers, sheets, or particles, and is embedded in
the other material called the matrix phase.
Typically, reinforcing materials are strong with low densities while the matrix is
usually a ductile or tough material. If the composite is designed and fabricated
correctly, it combines the strength of the reinforcement with the toughness of the
matrix to achieve a combination of desirable properties not available in any single
conventional material.
Composite Material
Two inherently different materials
that when combined together produce
a material with properties that exceed
the constituent materials.
Design Objective
Performance:
Composites
Composites are combinations of two materials in which one of the material is called
the reinforcing phase, is in the form of fibers, sheets, or particles, and is embedded
in the other material called the matrix phase.
Typically, reinforcing materials are strong with low densities while the matrix is
usually a ductile or tough material. If the composite is designed and fabricated
correctly, it combines the strength of the reinforcement with the toughness of the
matrix to achieve a combination of desirable properties not available in any single
conventional material.
Matrix materials
Interface
Polymers
Metals
Ceramics
Bonding
surface
Weight Considerations
Strength Considerations
Carbon is the strongest
600-800 ksi
5,650 MPa
Fiberglass
400-600 ksi
3,447MPa
Aramids
400 ksi
2,757 Mpa
Steel
77ksi
530MPa
Strength Considerations
Carbon is the strongest
600-800 ksi
Fiberglass
400-600 ksi
Aramids
400 ksi
Impact Resistance
Kevlar is the toughest
Fiberglass
Carbon
Stiffness Considerations
Carbon is the stiffest
30-40 msi
Aramids
14 msi
Fiberglass
10-13 msi
Cost Considerations
Fiberglass is cost effective
$5.00-8.00/lb.
Aramids
$20.00/lb
Carbon
$30.00-$50.00/lb
Fabric Structures
Woven:
Knit:
Physical Properties
Construction
Weight
Thickness
Weave
Type
Mary P. Shafer
Mary P. Shafer
Mary P. Shafer
Mary P. Shafer
Mary P. Shafer
Braiding
A braid consists of two sets of yarns, which are helically
intertwined.
The resulting structure is oriented to the longitudinal axis
of the braid.
This structure is imparted with a high level of
conformability, relative low cost and ease of manufacture.
Mary P. Shafer
Braid Structure
Mary P. Shafer
Types of Braids
Mary P. Shafer
Triaxial Yarns
A system of longitudinal yarns can be introduced which are held in
place by the braiding yarns
These yarns will add dimensional stability, improve tensile
properties, stiffness and compressive strength.
Yarns can also be added to the core of the braid to form a solid braid.
Mary P. Shafer
Conclusions
Composite materials offer endless design
options.
Matrix, Fiber and Preform selections are
critical in the design process.
Structures can be produced with specific
properties to meet end use requirements.
Mary P. Shafer
Composites
The essence of the concept of composites is that the load is applied over a
large surface area of the matrix. Matrix then transfers the load to the
reinforcement, which being stiffer, increases the strength of the composite. It
is important to note that there are many matrix materials and even more fiber
types, which can be combined in countless ways to produce just the desired
properties.
In the United States, composites manufacturing is a 25 billion dollar a year
industry. There are about 6000 composites related manufacturing plants and
materials distributors across the U.S. The industry employs more than
235,000 people. An additional 250,000 people are employed in businesses
that support the composites industry, including materials suppliers,
equipment vendors, and other support personnel.
About 90% of all composites produced are comprised of glass fiber and either
polyester or vinylester resin. Composites are broadly known as reinforced
plastics.
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Composites
Fibers
Matrix materials
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Application of Composites
Lance Armstrongs 2-lb.
Trek bike, 2004 Tour de
France
Pedestrian bridge in
Denmark, 130 feet long
(1997)
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Advantages of Composites
Higher Specific Strength (strength-to-weight 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.
The lowest properties for each material are associated with simple manufacturing processes
and material forms (e.g. spray lay-up glass fibre), and the higher properties are associated
with higher technology manufacture (e.g. autoclave moulding of unidirectional glass fibre),
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Mechanical Engineering Dept.
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the aerospace
industry.
Advantages of Composites
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 products 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.
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Advantages of Composites
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. This has
resulted in many creative and innovative companies in the field.
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. In a half-century of composites development, well-designed composite
structures have yet to wear out.
In 1947 the U.S. Coast Guard built a series of forty-foot patrol boats, using
polyester resin and glass fiber. These boats were used until the early 1970s when
they were taken out of service because the design was outdated. Extensive
testing was done on the laminates after decommissioning, and it was found that
only 2-3% of the original strength was lost after twenty-five years of hard
service.
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Application of Composites in
Aircraft Industry
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Disadvantages of Composites
Composites are heterogeneous
properties in composites vary from point to point in the material. Most
engineering structural materials are homogeneous.
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.
The experience and intuition gained over the years about the behavior of metallic
materials does not apply to composite materials.
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Disadvantages of Composites
Composites materials are difficult to inspect with conventional ultrasonic, eddy
current and visual NDI methods such as radiography.
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