Characteristics of a Composite Material

The constituents of a composite are generally arranged so that one or more discontinuous phases are embedded in a continuous phase. The discontinuous phase is termed the reinforcement and the continuous phase is the matrix. An exception to this is rubber particles suspended in a rigid rubber matrix, which produces a class of materials known as rubber-modified polymers. In general the reinforcements are much stronger and stiffer than the matrix. Both constituents are required, and each must accomplish specific tasks if the composite is to perform as intended. A material is generally stronger and stiffer in fiber form than in bulk form. The number of microscopic flaws that act as fracture initiation sites in bulk materials are reduced when the material is drawn into a thinner section. In fiber form the material will typically contain very few microscopic flaws from which cracks may initiate to produce catastrophic failure. Therefore, the strength of the fiber is greater than that of the bulk material. Individual fibers are hard to control and form into useable components. Without a binder material to separate them, they can become knotted, twisted, and hard to separate. The binder (matrix) material must be continuous and surround each fiber so that they are kept distinctly separate from adjacent fibers and the entire material system is easier to handle and work with. The physical and mechanical properties of composites are dependent on the properties, geometry, and concentration of the constituents. Increasing the volume content of reinforcements can increase the strength and stiffness of a composite to a point. If the volume content of reinforcements is too high there will not be enough matrix to keep them separate, and they can become tangled. Similarly, the geometry of individual reinforcements and their arrangement within the matrix can affect the performance of a composite. There are many factors to be considered when designing with composite materials. The type of reinforcement and matrix, the geometric arrangement and volume fraction of each constituent, the anticipated mechanical loads, the operating environment for the composite, etc., must all be taken into account.
Composite Materials Classifications

(0.02-100 pm). (whiskers) fibers suspended in a matrix material. Both continuous fibers and 0.0074 pin (3-200 pm) depending upon the fiber [3]. a very high length-to-diameter ratio. They are generally stronger and stiffer be broadly defined as having a length-to-diameter ratio of 5 < l/d < l00 and beyond [4]. Whisker diameters generally range between 0.787 and 3937 pin Composite materials are usually classified according to the type of reinforcement used. Two broad classes of composites are fibrous and particulate. Each has unique properties and application potential, and can be subdivided into specific categories as discussed below. Continuous Fibers. A continuous fiber is geometrically characterized as having Fibrous. A fibrous composite consists of either continuous (long) or chopped than bulk material. Fiber diameters generally range between 0.00012 and whiskers can be identified from a geometric viewpoint: Whiskers. A whisker is generally considered to be a short, stubby fiber. It can Composites in which the reinforcements are discontinuous fibers or whiskers can be produced so that the reinforcements have either random or biased orientation. Material systems composed of discontinuous reinforcements are considered single layer composites. The discontinuities can produce a material response that is anisotropic, but in many instances the random reinforcements produce nearly isotropic composites. Continuous fiber composites can be either single layer or multilayered. The single layer continuous fiber composites can be either unidirectional or woven, and multilayered composites are generally referred to as laminates. The material response of a continuous fiber composite is generally orthotropic.

Particulate. A particulate composite is characterized as being composed of particles suspended in a matrix. Particles can have virtually any shape, size or configuration. Examples of well-known particulate composites are concrete and particle board. There are two subclasses of particulates: flake and filled skeletal: Fluke. A flake composite is generally composed of flakes with large ratios of platform area to thickness, suspended in a matrix material (particle board, for example). FiZZed/SkeZetul. A filledskeletal composite is composed of a continuous skeletal matrix filled by a second material: for example, a honeycomb core filled with an insulating material. The response of a particulate composite can be either anisotropic or orthotropic. Such composites are used for many applications in which strength is not a significant component of the design. A schematic of several types of particulate composites is shown in Figure 1.4.
Figure

Composite Material Terminology

Some of the more prominent terms used with composite materials are defined below. Lamina. A lamina is a flat (or sometimes curved) arrangement of unidirectional (or woven) fibers suspended in a matrix material. A lamina is generally assumed to be orthotropic, and its thickness depends on the material from which it is made. For example, a graphite/epoxy (graphite fibers suspended in an epoxy matrix) lamina may be on the order of 0.005 in (0.127 mm) thick. For the purpose of analysis, a lamina is typically modeled as having one layer of fibers through the thickness. This is only a model and not a true representation of fiber arrangement. Both unidirectional and woven lamina are schematically shown in Figure 1.5.

Reinforcements. Reinforcements are used to make the composite structure or component stronger. The most commonly used reinforcements are boron, glass, graphite (often referred to as simply carbon), and Kevlar, but there are other types of reinforcements such as alumina, aluminum, silicon carbide, silicon nitride, and titanium.

Bulk moulding compound (BMC) or bulk molding composite is a ready to mold, fiber reinforced thermoset polyester material primarily used in injection moulding and compression moulding. The material is provided in bulk or logs.

BMC is manufactured by mixing strands (>1) of chopped glass fibers in a mixer with polyester resin. The glass fibers in BMC result in better strength properties than standard thermoplastic products. Typical applications include demanding electrical applications, corrosion resistant needs, appliance, automotive, and transit.

Fiber composite made from fibers and resin.

Bulk Molding Compound BMC is a combination of chopped glass strands and resin in the form of a bulk pre-preg. BMC is suitable for either compression or injection molding. Injection molding of BMC is used to produce complex components such as electrical equipment, car components, housings for electrical appliances and tools, in large industrial volumes. Unlike SMC, it is not necessary to include a maturation stage. Consequently, BMC pre-preg formulations contain higher filler contents. The chopped glass strands vary in length depending on the level of performance required. Reinforcement content generally ranges between 15 and 20 percent; however, it may reach 25 percent for the highest performance. BMC uses a lower reinforcement content than SMC and permits higher filler loadings with lower costs

Compression Molding Compression molding is done with matched metal molds utilizing sheet-molding compound (SMC), bulk-molding compound (BMC), or preform mat. A weighed charge of SMC or BMC, or a preform of glass reinforcement shaped to the mold is placed on a press ranging in size from 300 to 4,000 tons. Resin is added with the preform while SMC and BMC contain all components including fiber, resin, fillers, catalyst etc. Heat and pressure is applied, with temperature ranges of 225 to 325 oF. and 150 to 1,000 psi pressure required to cure parts. Cycles can range from less than one to five minutes. Typical thermoset resins used in compression molded parts are polyesters, vinyl esters, epoxies, and phenolics. Compression molded products vary from dinnerware, trays, buttons, appliance housings, large containers, electrical, to recreational vehicle body panels such as snow mobiles, and jetskis.
BAG MOLDING PROCESS

Pressure bag molding is similar to the vacuum bag molding method except that air pressure, usually 30 to 50 psi, is applied to a rubber bag, or sheet that covers the laid up composite to force out entrapped air and excess resin. Pressurized steam may be used instead, to accelerate the cure. Cores and inserts can be used with the process, and undercuts are practical, but only female and split molds can be used to make items such as tanks, containers, and wind turbine blades. Molding methods include vacuum bag, pressure bag, oven and autoclave molding. Bags, the thin and flexible membranes or silicone rubber shapes, separate the laid-up constructions from atmospheric pressure during composite cures. The bagged lay-ups in autoclaves are usually vented to pressures lower than those applied to the bag. Consolidations and densifications of the lay-ups are achieved by the resulting pressure differentials across the bag contents. Consolidations are achievedwhen the separate plies of prepreg in the layups and other adherents

are bonded together. Densifications result in reduction of voids and removal of excess resin. Other results desired of bag molding methods during cure include prevention of blistering in the composites, increased controls of pressure and heat application and control of the fiber/resin ratio. Consolidations and densifications of vacuum bag moldings can be achieved by atmospheric pressure alone as the bagged layups are evacuated throughout the cure cycles. The pressure-bagged and autoclaved-cured composites are pressurized by hot gases. Vents to the atmosphere or vacuum provide for the escape of the volatilized reaction by-products and the entrapped air from the curing composites. If the pressures within the bag are not reduced from those applied to the bag, the membrane remains inert and there is no compaction. Of the three methods, vacuum bag molding is least limited as to the size of constructions that can be processed. On a few occasions, 'wet' lay-up vacuum bag molded composites are room-temperature cured. Most are thermally cured to produce improved properties. Thermal cures are best attained in air circulating ovens/autoclaves, but can also be achieved in infrared heated and passive type convection ovens. Pressure bag molding methods are efficient for producing both deeply contoured structures and shallow composites. Sonar domes, radomes and antenna housings are examples of deeply contoured composites. Architectural panels, door panels and aircraft fairings are examples of shallow composites. Heavy molds are built to reproduce deeply contoured structures. Each specialized mold is constructed to withstand the elevated temperatures and increased pressures required for the cures. Shallow items may often be bag molded in modified compression presses. The lower press platens contain vents and vacuum lines. The upper press platens are made hollow to enclose the mold plates together with the laid

Structural Reaction Injection Molding (SRIM)

This process uses two resin components which are combined and mixed together, then injected into a mold cavity containing reinforcement. In the mold cavity, the resin rapidly reacts and cures to form the composite part.

Filament Winding
Filament winding consists of winding resin impregnated fibers or rovings of glass, aramid, or carbon on a rotating mandrel in predetermined patterns. The method provides the greatest control over fiber placement and uniformity of structure. In the wet method, the fiber picks up the low viscosity resin either by passing through a trough or from a metered application system. In the dry method, the reinforcement is in the preimpregnated form. After the layers are wound, the component is cured and removed from the mandrel. Traditionally used to produce pressure vessels, rocket motor cases, tanks, ducting, golf club shafts and fishing rods, filament winding technology has been expanded, and noncylindreical, nonspherical composite parts are now commonplace. Typical thermoset resins used in filament wound parts include polyesters, vinyl esters, epoxies, and phenolics.

Hand Lay-Up
Hand lay-up is the simplest and oldest open molding method of the composite fabrication processes. It is a low volume, labor intensive method suited especially for large components, such as boat hulls. Glass or other reinforcing mat or woven fabric or roving is positioned manually in the open mold, and resin is poured, brushed, or sprayed over and into the glass plies. Entrapped air is removed manually with squeegees or rollers to complete the laminates structure. Room temperature curingpolyesters and epoxies are the most commonly used matrix resins. Curing is initiated by a catalyst in the resin system, which hardens the fiber reinforced resincomposite without external heat. For a high quality part surface, a pigmented gel coat is first applied to the mold surface.

Continuous Lamination
Continuous Lamination makes composites in sheet form such as composite glazing, corrugated or flat construction panels, and electrical insulating materials. Reinforcement is combined with resin and sandwiched between two plastic carrier films. The sheet takes shape under forming rollers, and the resin is cured to form the composite.

Vacuum Bag Molding

Vacuum bag molding, a refinement of hand lay-up, uses a vacuum to eliminate entrapped air and excess resin. After the lay-up is fabricated on either a male or female mold from precut plies of glass mat or fabric and resin, a nonadhering film of polyvinyl alcohol or nylon is placed over the lay-up and sealed at the mold flange. A vacuum is drawn on the bag formed by the film while the composite is cured at room or elevated temperatures. Compared to hand lay-up, the vacuum method provides higher reinforcement concentrations, better adhesion between layers, and more control over resin/glass ratios. Advanced composite parts utilize this method with preimpregnated fabrics rather than wet lay-up materials and require oven or autoclave cures.

Pultrusion

Pultrusion is a continuous method of manufacturing various reinforced plastic shapes of uniform cross sections. Glass reinforcements, such as unidirectional rovings or multi-directional glass fiber mat, are guided through a liquid resin bath to thoroughly wet every fiber. The reinforcements are then guided and formed, or shaped, into the profile to be produced before entering a die. As the material progresses through the heated die, which is shaped to match the design profile, the resin changes from a liquid to a gel, and finally, into a cured, rigid plastic. A pulling device grips the cured material and literally pulls the material through the die. Hence, the name pultrusion. It is the power source for the process. After the product passes through the puller, it is sawed into desired lengths. Although pultrusion is ideally suited for custom shapes, some standard products include rods, bars, angles, channels, and I-beams.

Resin Transfer Molding (RTM)

Resin Transfer Molding (RTM) is a low pressure, closed molding process which offers a dimensionally accurate and high quality surface finish composite molding, using liquid thermoset polymers reinforced with various forms of fiber reinforcements. Typically polymers of Epoxy, Vinyl Ester, Methyl Methacrylate, Polyester or Phenolic are used with fiberglass reinforcement. Other reinforcements, are offered for more demanding applications such as Aramid, Carbon and Synthetic fibers either individually or in combination with each other. The matrix selection of polymer and reinforcement dictates both molding material cost, as well as molding mechanical and surface finish performance. Along with the polymer and

reinforcement the addition of mineral fillers may be added to enhance fire retardancy, flex modulus and surface finish. Reinforcements are presented in their dry form to the mold in either binder-bound chopped mat, random-continuous strand mat or woven cloth format. The fiber has been either "preformed" to the exact shape of the molding tool in a previous operation or is hand-tailored during the loading process in the molding tool. After the fiber is installed into the mold, a premixed catalyst and resin is injected into the closed mold cavity encapsulating the fiber within. The primary surface of the molding may be gel-coated, a process of spraying the mold surface before installing the fiber. If a gel coat is not required, the exterior finish would be the same from the front to back of the molded part. The RTM process has the inherent advantage of lowpressure injection, it usually does not exceed 100 psi of resin injection pressure during the moldfill process. The Benefits of using RTM

Closed Molding process is cleaner and healthier which attracts higher skilled employees. Closed Molding operator turn-over is dramatically reduced through improved working conditions. Closed Molding area has organized process flow to maximize throughput efficiency. Moldings can be manufactured to close dimensional tolerances. Components will have good surface finish on both sides. Selective reinforcement and accurate fiber management is achievable. Ability to build-in fiber volume fraction loadings up to 65%. Consistency in thickness and fiber loading, resulting in uniform shrinkage. Inserts may be incorporated into moldings. Tooling costs comparatively low compared to other manufacturing processes. Uses only low pressure injection. Low volatile emission during processing. Ability to produce near net shape moldings, reducing material wastage. Process can be automated, resulting in higher production rates with less scrap. Ability to mold complex structural and hollow shapes. Low resultant voidage in molded components. Ability to achieve from 0.1mm to 90mm laminate thickness.