ME 350 Lecture 15 Chapter 9

COMPOSITE MATERIALS:

1. Technology and Classification of Composite

Materials

2. Metal Matrix Composites

3. Ceramic Matrix Composites

4. Polymer Matrix Composites

5. Guide to Processing Composite Materials

Why Composites are Important

Composites can be very and , yet

very

in weight

Strength-to-weight ratio stiffness-to-weight ratios are several times greater than for steel or aluminum

properties are generally better than for common engineering metals

Toughness is often greater

Disadvantages and Limitations

1. Properties of many important composites are (properties differ depending on the direction in which they are measured)
May be an advantage or a disadvantage

2. Many of polymer-based composites are by chemicals or solvents

Just as the polymers themselves are susceptible

3. Composite materials are generally Manufacturing methods for shaping composite materials are often slow and costly

Components in a Composite Material

Most composite materials consist of two phases:

1.

phase - forms the matrix within which the

secondary phase is imbedded

2.

phase - imbedded phase sometimes referred to as a reinforcing agent, because it usually strengthens the composite material
The reinforcing phase may be in the form of fibers, particles, flakes or various other geometries

Classification of 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 3. Polymer Matrix Composites (PMCs) - polymer resins imbedded with filler or reinforcing agent
Examples: epoxy and polyester with fiber reinforcement, and phenolic with powders

Functions of the Matrix Material

phase provides the bulk form of the

part or product made of the composite material

Holds the imbedded phase in place, usually enclosing and often concealing it 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

The Reinforcing or Secondary Phase

Provide part

Imbedded phase is most commonly one of the

following shapes:

Carbide with 85% WC and 15% Co

Fiber Orientation Three Cases

One-dimensional reinforcement maximum strength and stiffness obtained in the direction of the fiber Planar reinforcement, i.e. two-dimensional woven fabric Random or three-dimensional in which the composite material tends to possess

Materials for Fibers

Fiber materials in fiber-reinforced composites

most widely used filament

high elastic modulus

Boron very high elastic modulus

Polymers - Kevlar
Ceramics SiC and Al2O3 Metals - steel

Particles and Flakes

A second common shape of imbedded phase is particulate, ranging in size from microscopic to macroscopic
Flakes are basically two-dimensional particles - small flat platelets

Distribution of particles in the composite matrix is random

Strength and other properties of the composite material are usually

The Interface
There is always an interface between constituent phases in a composite material For the composite to function, the phases must bond where they join at the interface

Interphase
In some cases, a third ingredient must be added to bond primary and secondary phases Called an interphase, it is like an

Three Factors that Determine Properties

1. Materials used as component phases in the

composite
2. Geometric shapes of the constituents and

resulting structure of the composite system

3. How the phases interact with one another

Example: Fiber Reinforced Polymer

Elastic modulus can be estimated by the rule of mixtures (equation 9.5 & 9.6). Fibers are typically stiff and brittle, while the matrix (commonly a polymer) is soft but ductile.

Variations in Strength and Stiffness

Variation in elastic modulus and tensile strength as a function of direction of measurement relative to longitudinal axis of carbon fiber-reinforced epoxy composite.

Composite Calculations
Density of a composite (weighted average): c = fm m + fr r Where are densities and fm and fr are the volume fractions of the matrix and reinforcing phases respectively Modulus of elasticity:
In the direction of the fibers: Ec = fmEm+ frEr Perpendicular to the direction of the fibers: Ec = EmEr /( fmEr+ frEm)

Other Composite Structures

Laminar composite structure conventional

Sandwich structure
Honeycomb sandwich structure

Laminar Composite Structure

Two or more layers bonded together in an integral piece Example: plywood, in which layers are the same wood, but grains are oriented differently to increase overall strength

Sandwich Structure: Foam Core

Relatively thick core of low density foam bonded on both faces to thin sheets of a different material

Sandwich Structure: Honeycomb Core

Alternative to foam core Foam or honeycomb achieve high ratios of strength-to-weight and stiffness-to-weight