Seminar on

Manufacturing of composite
material

under guidance of-

Prof. Dr. I. Basak
Raghvendra Kumar Pandey
10/ME/123
NIT Durgapur
 Composite materials:-

▪ A microscopic mixture of two or more different materials. One typically being the
continuous phase (matrix), and the other being the discontinuous phase (reinforcement).

▪ Its properties are strongly dependent on the composite structure.

21-Feb-14 Ceramic fiber composite Polymer matrix composite 2

 Why Composites?

▪ Composites can be very strong and stiff, yet very light in weight, so ratios of strength-to-weight and
stiffness-to-weight are several times greater than steel or aluminium.
▪ Reduces maintenance costs
▪ Reduces or eliminates corrosion
▪ Better fatigue resistance

▪ Less thermal expansion

▪ Enhanced properties via tailor able properties

– Mechanical Composite Aluminium Titanium
Steel Other
- Electrical
▪ Reduces cost Boeing 787 Composite Usage

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 Types of composites:- classification
Metal matrix
composites MMCs
Fiber • Ceramics + metals
• For example cemented carbides and other cermet's
• Aluminium or magnesium reinforced by strong, high stiffness fibers
Filled particle

composites Ceramic Matrix

Composites CMCs
• A ceramic primary phase imbedded with a secondary phase, which usually consists
of fibers
Laminar Flakes
• Least common composite matrix
• Aluminium oxide and silicon carbide are materials that can be imbedded with fibers
for improved properties, especially in high temperature applications
Polymer Matrix
Composites PMCs
• Thermosetting resins are the most widely used polymers in PMCs.
• Epoxy and polyester are commonly mixed with fiber reinforcement

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 Forms the matrix
Matrix material function:- within which the
secondary phase is
imbedded
A. Provides the bulk form of the part or product primary
B. Holds the imbedded phase in place Any of three basic
C. Shares the load with the secondary phase material types:
D. Polymer e.g. PEEK, Polyester, polyurethane, Rubber polymers, metals, or
ceramics
E. Metal e.g. Al, Cu, Ti, Ni
F. Ceramic e.g. cements, glass. Referred to as the
imbedded phase or
composite called the reinforcing
agent

Can be one of the

Reinforcement:- three basic materials
1. Rovings or an element such as
Secondary
carbon or boron

Serves to strengthen
continuous the composite
bulk
Continuous strand mat Chopped strand mat
Surface veils

Photomicrograph (about 1500X) of cemented carbide with

85% WC and 15% Co
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Laminated composite MMCs

Fiber reinforced polymer matrix

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CMCs
 Rule of mixture

▪ For particulate composites, the rule of mixtures predicts the density of the composite as well
as other properties (although other properties may vary depending on how the dispersed
phase is arranged)

▪ Density, r, is given as a fraction, f, as:

rc  fm rm  f f r f Note that f m  1  f f

Where the subscripts m and f refer to the matrix and fiber.

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 For fiber reinforced composites, the rule of mixtures predicts the density of the composite as well as
electrical and thermal conductivity along the direction of the fibers if they are continuous and unidirectional.

Density, r, is given as a fraction, f, as:

rc  fm rm  f f r f Note that f m  1  f f

For thermal conductivity: For electrical conductivity:

K c  fm K m  f f K f
 c  f m m
 f f f

 Thermal and electrical energy can be transferred through the composite at a rate that is proportional to the
volume fraction, f of the conductive material
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 Bulk of energy transferred through matrix
 But , in the fiber (polymer) composite, bulk energy transferred through fibers.
 When the fibers are not continuous or unidirectional, the simple rule of mixtures may not apply.
 For example, in a metal fiber-polymer matrix composite, electrical conductivity would be low and would depend
on the length of the fibers, the volume fraction of fibers and how often the fibers touch one another.
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 Manufacturing methods
1) Hand lay up
2) Pre- preg forming
3) Pressure moulding
4) Vacuum bagging
5) Filament winding
6) pultrusion
7) Spray method
8) Sheet moulding
9) Bulk moulding
10) Resin transfer moulding
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1) Hand lay up

 Low cost tools

 Versatile: wide range of
product

 Time consuming
 Possibility of trap of air
bubble
 inconsistance

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2) Prepreg forming

 orientation of fibers can

be changed
 consistent
 high productivity
 continuous process
needs more customers
 limited shelf life
 delamination

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3) Pressure forming
 Advantages:
 wide range of shapes
 integrate parts
 Consistency
 structural stability
 relatively simple

 Disadvantages
 high cost of machine
 expensive molds (strong
materials required)
 no intricate parts

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4) Vacuum bagging
 Advantages:
 simple design
 any fiber/matrix
combination
 better quality for the cost

 Disadvantages
 cannot be heated up too
much
 breeder clothe has to be
replaced frequently
 low pressure (760 mm Hg
the most)
 slowest speed
 inconsistency

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5) pultrusion

 Advantages:
 Automated processes.
 High speed.
 Versatile cross-sectional
shape.
 Continuous reinforcement

 Disadvantage :
 Die can be easily messed
up.
 Expensive die.
 Mainly thermoset matrix.

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6) Spray method:-
 Advantages :
 Continuous process
 Any materials can be used
as mold.
 Error can be corrected by
re-spraying.

 Disadvantages :
 Slow.
 inconsistency.
 No control of fiber
orientation.
 Only one side finished.
 Environmental unfriendly.

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7) Sheet moulding:

Advantages
High productivity thus
inexpensive
consistency

Disadvantages
low volume fraction.
Only board can be
made.

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8) Bulk moulding
Advantages
Highest volume fraction
for short fiber reinforced
composites (50%)
Good mechanical
properties
Finish can be applied
Inserts and attachments
possible

Disadvantages
High temperature and
high pressure
Random fiber
orientation
Cannot be used for
intricate parts

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 9) Resin transfer method:

Advantages
 good surface finish on both sides
 accurate fiber management is achievable
 Ability to build-in fiber volume fraction
loadings up to 65%
 Uniformity of thickness and fiber
loading, uniform shrinkage
 Inserts may be incorporated into moldings
 Tooling costs comparatively low
 Uses only low pressure injection
 Low volatile emission during processing
 Ability to produce near net shape moldings
 Process can be automated, resulting in higher
production rates
 Ability to mould complex structural and hollow
shapes
 Low resultant voids
 Ability to achieve from 0.5mm to 90mm
laminate thickness

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 conclusion

...And Just what is composite??

Let’s keep It simple 
▪ A macroscale material “composed” of multiple non homogenious material
▪ More simpler definition ?? Okay...

▪ Its STRING and GLUE ..!!

▪ Its everywhere...starting from MANGALYAAN to an OPERATION theater in

hospital.
▪ Why don’t customize the existing design when you have composite ...!!!

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