COMPOSITE MATERIALS

Dr.Suat CANOULLARI

Composite Material Defined

A materials system composed of two or more physically distinct phases whose combination produces aggregate properties that are different from those of its constituents Examples:
Cemented carbides (WC with Co binder) Plastic molding compounds containing fillers Rubber mixed with carbon black
2002 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 2/e

One Possible Classification of Composite Materials

1. Traditional composites composite materials that occur in nature or have been produced by civilizations for many years Examples: wood, concrete, asphalt 2. Synthetic composites - modern material systems normally associated with the manufacturing industries, in which the components are first produced separately and then combined in a controlled way to achieve the desired structure, properties, and part geometry
2002 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 2/e

Why Composites are Important

Composites are strong, stiff, light in weight, so strength-to-weight and are several times greater than steel or aluminum Fatigue properties are generally better than for common engineering metals Toughness is often greater too Composites can be designed that do not corrode like steel Possible to achieve combinations of properties not attainable with metals, ceramics, or polymers alone
2002 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 2/e

Disadvantages and Limitations of Composite Materials

Composites are anisotropic - the properties differ depending on the direction in which they are measured this may be an advantage or a disadvantage Many of the polymer-based composites are subject to attack by chemicals or solvents, just as the polymers themselves are susceptible to attack Composite materials are generally expensive Manufacturing methods for shaping composite materials are often slow and costly and Gradually they have a low temperature strength against to metals
2002 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 2/e

Components in a Composite Material

All composite materials consist of two phases: 1. Primary phase - forms the matrix within which the secondary phase is imbedded 2. Secondary phase - imbedded phase sometimes referred to as a reinforcing agent, because it usually serves to strengthen the composite The reinforcing phase may be in the form of fibers, particles, or various other geometries
2002 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 2/e

Composite Materials
1. Metal Matrix Composites (MMCs) - mixtures of ceramics and metals, such as cemented carbides and other cermets 2. Ceramic Matrix Composites (CMCs) - Al2O3 and SiC imbedded with fibers to improve properties, especially in high temperature applications The least common composite matrix 3. Polymer Matrix Composites (PMCs) - thermosetting resins are widely used in PMCs Examples: epoxy and polyester with fiber reinforcement, and phenolic with powders
2002 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 2/e

Functions of the Matrix Material

Provides the bulk form of the part Holds the imbedded phase in place When a load is applied, the matrix shares the load with the secondary phase, in some cases deforming so that the stress is essentially born by the reinforcing agent

2002 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 2/e

Matrix Considerations
End Use Temperature Toughness Cosmetic Issues Flame Retardant Processing Method Adhesion Requirements

The Reinforcing Phase (Secondary Phase)

Function is to reinforce the primary phase Imbedded phase is most commonly one of the following shapes: a) Fibers b) Particles c) Flakes In addition, the secondary phase can take the form of an infiltrated phase in a skeletal or porous matrix Example: a powder metallurgy part infiltrated with polymer
2002 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 2/e

Types of Fibers
Fiber Glass

Graphite Fiber

Kevlar Fiber

11 Kevlar/Carbon Hybrid

Composite Survey
Composites
Particle-reinforced Fiber-reinforced Structural

Largeparticle

Dispersionstrengthened

Continuous (aligned)

Discontinuous (short)

Laminates

Sandwich panels

Aligned

Randomly oriented

Adapted from Fig. 16.2, Callister 7e.

Composite Survey
Particle-reinforced -- two approaches.
E(GPa) 350 Data: Cu matrix 30 0 w/tungsten 250 particles 20 0 150 0

Fiber-reinforced

Structural

Elastic modulus, Ec, of composites:

upper limit: rule of mixtures Ec = VmEm + VpEp lower limit: 1 Vm Vp = + c Em Ep E
20 4 0 6 0 8 0 10 0 vol% tungsten
Adapted from Fig. 16.3, Callister 7e. (Fig. 16.3 is from R.H. Krock, ASTM Proc, Vol. 63, 1963.)

(Cu)

(W)

Application to other properties:

-- Electrical conductivity, se: Replace E in the above equations with se. -- Thermal conductivity, k: Replace E in above equations with k.

Composite Survey: Fiber

Particle-reinforced Fiber-reinforced Structural

Fibers themselves are very strong

Provide significant strength improvement to material Properties are Determined by Three Factors: The materials, The geometric shapes of the constituents and Resulting structure of the composite system

Figure 9.5 - (a) Model of a fiber-reinforced composite material showing direction in which elastic modulus is being estimated by the rule of mixtures (b) Stress-strain relationships for the composite material and its constituents. The fiber is stiff but brittle, while the matrix (commonly a polymer) is soft but ductile.
2002 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 2/e

Figure 9.6 - Variation in elastic modulus and tensile strength as a function of direction of measurement relative to longitudinal axis of carbon fiber-reinforced epoxy composite
2002 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 2/e

Fiber Alignment
Adapted from Fig. 16.8, Callister 7e.

aligned continuous

aligned random discontinuous

Composite Strength: Longitudinal Loading

Continuous fibers - Estimate fiber-reinforced composite
strength for long continuous fibers in a matrix Longitudinal deformation

sc = smVm + sfVf
volume fraction

but

c = m = f
isostrain

Ece = Em Vm + EfVf

longitudinal (extensional) modulus Remembering: E = s/ f = fiber m = matrix

and note, this model corresponds to the upper bound for particulate composites

Ff E fVf Fm E mVm

Composite Strength: Transverse Loading

In transverse loading the fibers carry less of the load and are in a state of isostress
sc = sm = sf = s
1 Vm Vf E ct E m E f

c= mVm + fVf

transverse modulus
Remembering: E = s/ and note, this model corresponds to the lower bound for particulate composites

An Example:
UTS, SI 57.9 MPa 2.4 GPa Modulus, SI 3.8 GPa 399.9 GPa

(241.5 GPa)

(9.34 GPa)

Note: (for ease of conversion) 6870 N/m2 per psi!

Composite Survey: Structural

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.