Composite

Materials

Composite Materials:
Definition
A multi-component solid consisting of
two or more different materials
Each of the components retains its
identity and maintains its
characteristic structure and properties
There are recognizable interfaces
between the components

Composite Materials:
The composite generally exhibits a
combination of properties (including
stiffness, strength, conductivity, etc.)
not possible with the individual
components
The components can be metals,
ceramics, polymers, or even natural
materials such as wood, stone, or
straw
Hence a wide range of freedom exists
and composite materials can often be
designed to meet a desired set of
properties and characteristics

Classification by Geometry

Laminar
Particulate
Dispersion strengthened
True particulate

Fiber reinforced

Laminar (layered) Composites:

Includes thin coatings, thick protective
surfaces, claddings, bimetallics,
laminates, and sandwiches
Properties are anisotropic (different
within the layers and perpendicular to
the layers)
Used to impart properties such as: low
cost, corrosion resistance, wear
resistance, electrical properties, unique
expansion characteristics, light weight,
enhanced strength, or altered
appearance

Laminar (layered) Composites:

Examples:
Plywood (laminate)overcomes grain
orientation by bonding layers at
various angles, increases strength &
fracture resistance, isotropic within
the plane

Laminar (layered)
Composites:

Examples:

Safety glass (glass and polymer)

- In this process, two

sheets of glass are bonded together with a layer of plastic (the
plastic layer goes inside the two glass sheets). The lamination
takes place in an autoclave, a special oven that uses both heat
and pressure to form a single, strong unit that is resistant to
tearing. The plastic interlayer is often tinted to act as an ultraviolet
filter. When laminated glass is broken, the broken pieces of glass
remain bound to the internal tear-resistant plastic layer, and the
broken sheet remains transparent. Thus, visibility remains good.

Laminar (layered) Composites:

Bi-metallic strips - two metals with different coefficients of thermal expansion, composite offers shape as a function of
temperature (thermostat material)

Laminar (layered) Composites:

Examples (cont)
U.S. Coins
Claddingsoffer enhanced surface
with low cost, can have high strength
or light weight core
Examples:
AlClad aluminum clad aluminum
Stainless claddings on steel

Laminar (layered) Composites:

Honeycomb - Corrugated cardboard, honeycomb, & other sandwichesthick, low density core with high density surfaces,
strong but light weight

Particulate Composites:

Discrete particles of one material

in a matrix of another

Dispersion-strengthened
particulates
Small amounts of hard, brittle, small
particles dispersed in a softer, ductile matrix
Good bonding between particles and matrix
Strengthening persists at elevated
temperatures (dispersant not soluble in
matrix so it doesnt redissolve, overage, or
overtemper)
Good creep resistance
Usually produced via powder metallurgy
Examples:
SAP (sintered aluminum powder aluminum
metal and aluminum oxide ceramic, up to
14% ceramic)
TD-Nickel (Thoria-dispersed nickel nickel

True particulate composites:

Large amounts of rather coarse particles form the bulk of the composite
-usually, properties are isotropic
Concretesand and
gravel in cement

Asphaltcrushed
aggregate in bitumen
(a thermoplastic binder)

True particulate composites:

Cemented carbides
ceramic particles in a metal
matrix which provides
toughness

Grinding wheelsceramic
abrasives in a glass or
polymer matrix

True particulate composites:

Electrical contactstungsten + copper or
silver

Fiber-reinforced composites:
Generally seeks enhanced strength,
fatigue resistance, stiffness or
strength-to-weight ratio by
incorporating strong, stiff, but
possibly brittle fibers into a softer,
more ductile matrix

Fiber-reinforced composites:
Fibers
Carry most of the load
Impart enhanced stiffness

Matrix

Supports fibers
Transfers load to fibers
Protects fibers
Provides ductility & toughness

Fiber-reinforced composites:
Examples
WoodCellulose fibers in
lignin matrix
Primitive bricks of straw and
mud
Auto tires use nylon, rayon,
Kevlar, or steel fibers to
provide strength and
durability to rubber

Golf club shafts (graphite +

epoxy)

Fiber-reinforced composites:
Design featuresthe properties of
fiber-reinforced composites depend
on a number of factors, including:

Properties of the fiber material

Volume fraction of the fibers
The aspect ratio of the fibers
Orientation effects
Degree of bonding between the fiber and
matrix
Properties of the matrix

 Fiber properties
Generally want strong, stiff, and
lightweight
Specific strength = Y.S. / density
Specific stiffness = Modulus / density
If used at high temperatures, may want
high melting point fibers
Glass
Usually combined with epoxy or polyester
matrix using 30-60% fiber
Low cost
Various types of glass are used

Graphite
Has negative coefficient of thermal expansion

 Kevlar (poly paraphenylene

terephthalamide)

TS -- 450 ksi
E -- 16 x 106 psi
Density ~ Aluminum
Negative thermal expansion

Ceramic fibers
Alumina
Silicon carbide

Metal fibers
Tungsten, beryllium, boron

Whiskers
Metal, graphite, ceramics

 Volume fraction of fibers

More fibers provide greater strength and
stiffness
Max is 80% to permit a continuous
matrix

Aspect ratio of fibers

Length/diameter ratio
Higher ratio greater strength
Smaller diameter less surface area for
flaws stronger fiber

 Orientation effects
Short, randomly
oriented fibers
Unidirectional fibers
good strength
parallel to fibers, but
poor properties in
other direction
Woven fabrics or
tapes
3-D stitching of
woven plies

Fiber orientation

Fiber orientation

 Degree of fiber-matrix bonding

Want strong bonding in polymer and
metal matrix composites
Want weak bonding in ceramic matrix
materials

Matrix properties
Matrix materials should be strong, tough,
and ductile so they can transmit the
loads to the fibers and prevent cracks
from propagating through the composite
They also provide the major component
of electrical properties, chemical
behavior, and elevated temperature
stability

Types of Composite Matrices

Polymer matrixuseful up to 600F
Thermosetsrequires curing around fibers
Thermoplasticscan embed fibers in melted
resin
Examples: sheet molding compound and bulk
molding compound

Metal matrix

Permits higher operating temp

High stiffness and strength at elevated temp
Low thermal expansion
Enhanced resistance to fatigue, abrasion and
wear
Good electrical and thermal conductivity
Common forms include Al, Cu, Mg, Ti, Ni or
superalloy matrix with graphite, boron
carbide, aluminum oxide, or silicon carbide
fibers, or even high-temperature metal wires

 Carbon matrix with graphite fibers

Low density, useful strength up to 6000F

Ceramic matrix
Lightweight and adequate properties at high temp
Both glass and crystalline ceramics are used
Fiber reinforcements improve toughness
Delaminate
Pull free
Hold cracks together

 Assets of fiber-reinforced composites

High strength and stiffness
Light weight
Enhanced fatigue life
Corrosion resistant

 Possible limitations of fiber

composites
High costmaterial and fabrication
Difficult to inspect
Hard to predict properties
Response to impact
Failure conditions
Environmental response

Often fails in a brittle manner

Limited ability to be repaired if
damaged
Recycling is difficult
Assembly (joining) usually requires
adhesives

Factors determining composite

properties
The properties of the components
The relative amounts of the
components
Size, shape and distribution of the
discontinuous components
Orientation of the various
components
Degree of bonding between the
components

 Rule of Mixtures:
Property of the composite is simply a
weighted average of the properties of
its components
Uses volume fractions of the
components

Xcomposite = XAVolA + XBVolB +

.

 Rule of Mixtures is always good for

density.
Depending on orientation, Rule of
Mixtures may be good for modulus
and conductivity
Rule of Mixtures should NOT be relied
upon for mechanical properties such
as: strength, ductility, toughness,
fatigue, creep and wear

Factors determining composite

properties
The properties of the components
The relative amounts of the
components
Size, shape and distribution of the
discontinuous components
Orientation of the various
components
Degree of bonding between the
components

Advanced Composites:
Specifically designed for:
High specific strength
High specific modulus
Good temperature resistance

Property Comparisons
Strength and modulus
Strength vs. Temperature

Properties of some selected composites

Properties vs
Temperature

High temperature
turbine rotors

SiC whiskers in a silicon nitride matrix

Fabrication of composite
shapes:
Die methods
Casting
Pultrusion
Filament winding

Producing composite shapes in

dies

Producing composite
shapes by casting

Producing composite
shapes by pultrusion

Honeycomb structures

Honeycomb structures

Laminar composite