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Composites
Reading: Callister Ch. 15
Issues to address I dd What are composites? Classification of composites. Why composites? Mechanical properties of composites. Applications.
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Bicycle forks
Braided and unidirectional S-2 Glass and carbon fibers are used to produce forks with different stiffness
From http://matse101.mse.uiuc.edu/
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Pole-vaulting
Lightweight g t eg t Buckling resistance Strong Minimal twisting Cost - low o density de s ty - stiffness - yield strength
From http://matse101.mse.uiuc.edu/
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Boeing 757-200
Flap support fairings Fwd segment (graphite/Kevlar + non-woven Kevlar mat Aft segment (graphite/fiberglass) Ailerons (graphite) Engine strut fairings (Kevlar/fiberglass) Environmental control system ducts (Kevlar) Aft flaps Outboard (graphite) Inboard (graphite/fiberglass) Tip fairings (fiberglass) Rudder (graphite) Fixed trailing edge panels graphite /Kevlar + nonwoven Kevlar mat) Elevators (graphite) Fixed trailing edge panels upper (graphite /fiberglass), lower (graphite /Kevlar + non-woven Kevlar mat) Fixed trailing edge panels Graphite/Kevlar + non-woven Kevlar mat
Nose landing gear doors (graphite) Wing to body fairings (graphite/Kevlar/Fiberglass and Graphite/Kevlar + nonwoven Kevlar mat
Spoilers (graphite) Wing leading edge lower panel Cowl components Kevlar/fiberglass (graphite) Body main landing gear doors (graphite) Trunnion fairings and wing landing gear doors (graphite/Kevlar) Brakes( structural carbon)
From http://matse101.mse.uiuc.edu/
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Terminology
Matrix:
softer, more flexible and continuous part that surrounds the other phase. transfer stress to other phases protect phases from environment
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Composite characteristics
Depends on: - properties of the matrix material. - properties of reinforcement material. - ratio of matrix to reinforcement. - matrix-reinforcement bonding/adhesion. - mode of fabrication.
7 orientation distribution concentration size shape
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Classification of Composites
Matrix-based:
Metal Matrix Composites (MMC) Ceramic Matrix Composites (CMC) Polymer Matrix Composites (PMC)
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COMPOSITE BENEFITS
CMCs: Increased toughness
Force
particle-reinf
PMCs: Increased E/
ceramics
10 3 E(GPa) PMCs 10 2 10
Bend d isplacement 10 -4 1) ss (s -1 10 -6 10 -8
MMCs:
(MPa) 10 0 200
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Reinforcement-based
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Fiber -reinforced
Structural
particles: cementite (Fe 3 C) (brittle)
Adapted from Fig. 10.10, Callister 6e. (Fig. 10.10 is copyright United States Steel Corporation, 1971.)
60 m
Adapted from Fig. 16.4, Callister 6e. (Fig. 16.4 is courtesy Carboloy Systems, Department, General Electric Company.) Company )
-Automobile tires
From Callister resources CD
Adapted from Fig. 16.5, Callister 6e. (Fig. 16.5 is courtesy Goodyear Tire and Rubber Company.)
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Fiber -reinforced
Structural
(Cu)
(W)
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Fiber-reinforced composites
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Fiber-reinforced composites
The Fiber Phase
Smaller diameter fiber is stronger than bulk in most materials ( (especially i ll b brittle i l ones). ) Wh Why? ? Flaws! Whiskers: very thin single crystals that have extremely large aspect ratios. high degree of crystallinity and virtually flaw free exceptionally high strength. usually extremely expensive. some whisker materials: graphite, SiC, silicon nitride, aluminum oxide. Fibers: polycrystalline or amorphous. typically: polymers or ceramics (polymer aramids, glass, carbon, boron, SiC Fine Wires: relatively large diameter, often metal wires. e.g. steel, molybdenum, tungsten 2007, 2008 Moonsub Shim
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Fiber-reinforced composites
The Matrix Phase
can
typically metals and polymer because some ductility is often desired. main functions of the matrix: -Hold fibers together. -Transmit and distribute external stress to the fibers. -Protect fibers from surface damage: abrasions, chemical reactions in CMCs, reinforcements are usually added to improve fracture toughness .
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Fiber-reinforced composites
The Fiber-Matrix Interface
1.
2.
Electrostatic attraction
+ + + + + + + - - - - - -
- - - + + + -
+ -
- + + -
Depends on surface charge density. e.g. glass fibers, polymers with chargeable groups.
3.
Covalent bonding
Usually the strongest fiber-matrix fiber matrix interaction. The most important in many composites.
A B A B A B
4.
Mechanical adhesion
Interlocking of 2 rough surfaces e.g. thermosetting resins
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Fiber-reinforced composites
Properties depend on LENGTH and ORIENTATION of the fibers (as well as isolated properties of each of the components)! Critical fiber length
* fd lc = 2 c
* f =
d= c =
Fiber tensile strength Fiber diameter Smaller of: fiber-matrix bond strength matrix shear yield strength.
Continuous when fiber length >> lc Discontinuous when fiber length < 15 lc
Possible failure modes: 1) fiber breaking. 2) matrix breaking. 3) fiber pullout (interface between fiber and matrix fails)
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Fiber-reinforced composites
Short fibers
(x)
Long fibers
(x)
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Aligned fibers
Continuous when fiber length >> lc Discontinuous when fiber length < 15 lc
Elastic Modulus
Not so detrimental since: 1) Not all fibers fail at the same time 2) Matrix still intact
0o
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Structural
(a)
fracture surface
From F.L. Matthews and R.L. Rawlings, Composite Materials; Engineering and Science, Reprint ed., CRC Press, Boca Raton, FL, 2000. (a) Fig. 4.22, p. 145 (photo by J. Davies); (b) Fig. 11.20, p. 349 (micrograph by H.S. Kim, P.S. Rodgers, and R.D. Rawlings). Used 20 with permission of CRC Press, Boca Raton, FL. MSE280
2 m
(b)
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Continuous-aligned fibers
Consider a composite with fibers having square rod geometry with stress in the longitudinal
direction
fiber B
b B Matrix L
When l >> lc (typically l > 15 lc), ) we can simplify to: l then Lcomposite = L fiber = Lmatrix B b 2007, 2008 Moonsub Shim
L since , l
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Continuous-aligned fibers
Longitudinal loading
What about elastic modulus? Total force on the composite is simply the sum of forces on matrix and fibers: l
since
F A
or
F = A
c Ac = m Am + f A f
Sub-in for stresses
= E
Ec c Ac = Em m Am + E f f A f
Imposing isostrain condition c
rearrange
Ec =
= f = m ,
Em m Am E f f A f + c Ac c Ac
Ec = E m
Af Am + Ef Ac Ac
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Continuous-aligned fibers
Longitudinal loading
Total area = Bb Af = number of fibers x area of each fiber = Then we have: Af Ac = Nb B Also, Nb2 l
Am = Ac A f or Af Am Nb = 1 = 1 Ac Ac B
V f = Nb 2l
Then: v f =
Vf Vc
Nb 2l Nb A f = = Bbl B Ac
Similarly,
vm =
Am Ac
Ecl = vm Em + v f E f
Longitudinal elastic modulus 23 (upper bound for Ec) MSE280
Continuous-aligned fibers
Longitudinal loading
What about the load on the matrix and the fibers? l
Ff Fm
Ff Fm
With
=?
F = A
f Af f v f = m Am m vm
= E
= Ef f vf E m m vm
Isostrain conditions
Ff Fm
Ff Fm
Ef vf E m vm
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Continuous-aligned fibers
Transverse loading
Stress, rather than strain, is the same in this case: B
c = f = m
ISOSTRESS condition
Lc = L f + Lm
Strain = c =
Lc L f Lm = + Lc Lc Lc
L f = Nb Lf Nb = vf = Lc B
Rearrange
Lc =
Lf vf
Similarly,
Lc =
Lm vm
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Continuous-aligned fibers
Transverse loading
L L L c = c = f + m Lc Lc Lc L f L f Lm L = + = vf + vm m Lm L f / v f Lm / vm Lf
l B b
c = vm m + v f f
c
Ec = vm
m
Lower bound for Ec (transverse modulus)
m
Em
+ vf
f
Ef
Ect =
Em E f vm E f + v f E m
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Applying isostress condition and rearranging gives 2007, 2008 Moonsub Shim
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Continuous-aligned fibers
Many properties follow these upper and lower bound relations for continuous-aligned fiber composities. In general: l B b
cl = cupper = vm m + v f f
ct = clower =
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m f vm f + v f m
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2. 3.
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Continuous-aligned fibers l
Tensile strength
Longitudinal:
* ' * cl l = vm m + v f f
This is assuming that the fiber fails prior to the matrix. ' m = Stress in the matrix at failure
* f =
Transverse: more complex due to many factors that affect it (e.g. matrix & fiber properties, fiber-matrix bond strength, presence of voids etc)
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lc ' + m vm 2l
If l < lc
* cd ' =
= l c ' vf +m vm c d
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C fibers: very stiff y strong g very C matrix: less stiff less strong fibers lie in plane
Ec = Em Vm + KE f Vf
efficiency factor (depends on vf and Ef/Em): --aligned 1D: K = 1 (anisotropic) --random 2D: K = 3/8 (2D isotropy) --random 3D: K = 1/5 (3D isotropy)
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Some applications: fishing rods, golf clubs, bicycles, military and commercial aircraft structural components
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Carbon-carbon composites
Carbon fiber reinforced carbon matrix p composites.
High modulus & TS (retained to T > 2000oC). Resistant to creep. Large fracture toughness. Small thermal expansion coefficient. High thermal conductivity. Uses: rocket motors, friction material for aircraft and hi h high-performance f automobile t bil b brakes, k components t f for turbine engines Very expensive mainly due to relatively complex processing.
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1m
Nanotube bundles
Ajayan et al.
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Pultrusion
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Design example
F
Requirements
A) Which fiber(s), if embedded in epoxy matrix, meet the these criteria? B) Decide D id on th the most t cost-effective t ff ti fiber. fib
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Concepts to remember
Matrix & reinforcement. What composite characteristics depend on. Classification Cl ifi ti : matrix-based ti b d MMC, MMC CMC CMC, PMC; PMC reinforcement-based. Particle reinforced composites: upper and lower bound for E (rule of mixtures). Fiber-reinforced composites Continuous-aligned, discontinuous-aligned & discontinuous-random cases. Critical Cii ll length. h Longitudinal & transverse properties. Isostrain & isostress cases. Structural composites.
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