ME 1014

Composite Materials

Prof.V.Alfred Franklin.,
St.Xavier’s Catholic College of Engineering
Nagercoil, India.
 Composite Material ?
Two inherently different materials that when combined together
produce a material with properties that exceed the constituent
materials.

Any combination of two or more different materials at the

macroscopic level..

The constituents retain their identities, i.e.., they do not dissolve

or merge into each other, although they act in concert.

Composites: Artificially produced multiphase materials.

 Composite Material ?
 Composites: A judicious combination of two
or more materials that produces a synergistic
effect.
A material system composed of two or more
physically distinct phases whose combination
produces aggregate properties that are
different from those of its constituents.
 Phases of Composites

Matrix Phase: continuous phase, surrounds other phase

(e.g.: metal (Cu, Al, Ti, Ni…); , ceramic (SiC…), or polymer (Thermosets,
thermoplastics, Elastomers)

Reinforcement Phase: dispersed phase, discontinuous phase

(e.g.: Fibers, Particles, or Flakes)

􀂃 → Interface between matrix and reinforcement

Interfacial properties - the interface may be regarded as a third phase.

Examples:
– Straw in mud
– Wood (cellulose fibers in hemicellulose and lignin)
– Bones (soft protein collagen and hard apatite minerals)
– Pearlite (ferrite and cementite)
Micro mechanics/ Macro mechanics?
 Major Constituents

Fiber
Matrix
Fillers
Coupling agents
Colorants
 FIBERS
Principle Load carrying member

Main constituent and they occupy largest

volume fraction

Diameter of a single fiber is about 10

microns

They may be continuous or discontinuous

in length.
 TYPES OF GLASS FIBER
 E-Glass – E stands for electrical
 S-Glass – S stands for high silica content
 High thermal expansion coefficient
 High fatigue strength
 C-Glass – C stands for Corrosion
 Used in Chemical applications
 Storage tanks
 R-Glass – R stands for Rigid
 Structural applications
 D-Glass – D stands for Dielectric
 Low dielectric constants
 A-Glass – A Stands for appearance
 To improve surface appearance
 For ornamental works
 E-CR Glass – E-CR stands for Electrical and corrosion
resistance
 AR Glass – AR stands for Alkali resistance
• Critical fiber length for effective stiffening & strengthening:

fiber strength in tension fiber diameter

f d
fiber length  15 shear strength of
c fiber-matrix interface
 Efficiency : fiber length

Shorter, thicker fiber: Longer, thinner fiber:

 d  d
fiber length  15 f fiber length  15 f
c c

7
Poorer fiber efficiency Better fiber efficiency
 Why are Fibers of a Thin Diameter?
1. Thinner fiber has higher ultimate strength because less chance
for inherent flaws. Similar phenomenon in metals and alloys
(Strength of a thin wire can be higher than its bulk material).

2. For the same volume of fibers, thinner fibers has larger

surface area thus has stronger bond with matrix. (The total
surface area of fibers is inversely proportional to the diameter
of fibers)

3. Thinner fiber has larger flexibility ( 1/(EI)) and therefore is

able to be bent without breaking (Woven fabric performs can
be made before impregnated with polymer matrix).
 Composite Strength: Longitudinal Loading

Continuous fibers - Estimate fiber-reinforced composite

strength for long continuous fibers in a matrix
 Longitudinal deformation
c = mVm + fVf but c = m = f
volume fraction isostrain

 Ec = Em Vm + EfVf longitudinal (extensional)

modulus
Ff E f Vf Remembering: E = /
 f = fiber and note, this model
Fm E mVm m = matrix corresponds to the
“upper bound” for
C-composite particulate composites
 Matrix / Resins

- The resin or polymer is the “glue” that holds

the composite together

-The primary functions of the resin are to

transfer stress between the reinforcing fibers.

Examples: Polyester, Epoxy, Vinyl Ester, Polyurethane

 Role of Matrices in Composites

 Transfer stresses between the fibers.

 Provide a barrier against an adverse environment.
 Protect the surface of the fibers from mechanical
abrasion.
 Determine inter-laminar shear strength.
 Determine damage tolerance of composites.
 Determine in-plane shear strength.
 Determine the processibility of composites.
 Determine heat resistance of composites.
 Role of Matrix
 The primary roles of the matrix alloy then are to provide
efficient transfer of load to the fibers and to blunt cracks in
the event that fiber failure occurs and so the matrix alloy for
continuously reinforced composites may be chosen more for
toughness than for strength.

 On this basis, lower strength, more ductile, and tougher

matrix alloys may be utilized in continuously reinforced
composites.

 For discontinuously reinforced composites, the matrix may

govern composite strength.
-Then, the choice of matrix will be influenced by consideration
of the required composite strength and higher strength matrix
alloys may be required.
 Functions of Matrix
 Holds the fibres together.
 Protects the fibres from environment.

 Distributes the loads evenly between fibres so that all fibres are
subjected to the same amount of strain.

 Enhances transverse properties of a laminate.

 Improves impact and fracture resistance of a component.

 Helps to avoid propagation of crack growth through the fibres by

providing alternate failure path along the interface between the
fibres and the matrix.

 Carry inter-laminar shear.

 Desired Properties of a Matrix
 Reduced moisture absorption.

 Low shrinkage.

 Low coefficient of thermal expansion.

 Good flow characteristics so that it penetrates the

fibre bundles completely and eliminates voids during
the compacting/curing process.

 Must be elastic to transfer load to fibres.

 Desired Properties of a Matrix

 Reasonable strength, modulus and elongation

(elongationshould be greater than fibre).

 Strength at elevated temperature (depending on application).

 Low temperature capability (depending on application).

 Excellent chemical resistance (depending on application).

 Should be easily processable into the final composite shape.

 Dimensional stability (maintains its shape).

 FILLERS
 Control Composites’ Cost
 Improved Mechanical Properties
 Improved Chemical Properties
 Reduced Creep & Shrinkage
 Low Tensile Strength
 Fire Retardant & Chemical Resistant
TYPES OF FILLER
 Calcium Carbonate
 Kaolin
 Alumina Trihydrate
 Mica Feldspar
 Wollastonite
 Silica, Talc, Glass
 ADDITIVES
 Improved Material Properties
 Aesthetics
 Enhanced Workability
 Improved Performance
ADDITIVE TYPES
 Catalysts
 Promoters
 Inhibitors
 Coloring Dyes
 Releasing Agents
 Antistatic Agents
 Foaming Agents
 Composites Offer
High Strength to weight ratio
High Stiffness to weight ratio
High Modulus to weight ratio
Light Weight
Directional strength
Corrosion resistance
Weather resistance
Dimensional stability -low thermal conductivity
-low coefficient of thermal expansion
Radar transparency
Non-magnetic
High impact strength
High dielectric strength (insulator)
Low maintenance
Long term durability
Part consolidation
Small to large part geometry possible
Tailored surface finish
Design Flexibility
 Property comparison
Tensile Density
Tensile Specific Specific
modulus ( )
Material strength(  u ) modulus strength
(E) ( g / cm 3 )
( GN / m 2 ) (E/ ) ( u /  )
( GN / m 2 )

E-Glass 72.4 3.5 2.54 28.5 1.38

Graphite 390.0 2.1 1.90 205.0 1.1
Boron 385.0 2.8 2.63 146.0 1.1
Kevlar – 49 130 2.8 1.50 87 1.87
0.043 –
Steel 210 0.34 – 2.1 7.8 26.9
0.27
Aluminum 0.052 –
70 0.14 – 0.62 2.7 25.9
alloys 0.23
Composite strength depends on the following
factors:
 Inherent fiber strength,
Fiber length, Number of
flaws
 Fiber shape
 The bonding of the
fiber (equally stress
distribution)
 Voids
 Moisture (coupling
agents)
 Classification of Composite Materials
1. Traditional composites – composite materials that
occur in nature or have been produced by civilizations
for many years
 Examples: wood (cellulose fibers in lignin matrix),
concrete, asphalt

2. Synthetic composites - modern material systems

normally associated with the manufacturing
industries, in which the components are first
produced separately and then combined in a
controlled way to achieve the desired structure,
properties, and part geometry
Classification of Synthetic Composites: Based on Matrix

Matrix Metal Ceramic Polymer

Reinforcement
Metal Powder metallurgy parts – Cermets (ceramic-metal Brake pads
combining immiscible composite)
metals

Ceramic Cermets, TiC, TiCN SiC reinforced Al2O3 Fiberglass

Cemented carbides – used Tool materials
in tools
Fiber-reinforced metals

Polymer Kevlar fibers in an

epoxy matrix

Elemental Fiber reinforced Rubber with carbon

(Carbon, Boron, metals (tires)
Auto parts Boron, Carbon
etc.)
aerospace reinforced plastics

MMC’s CMC’s PMC’s

Metal Matrix Composites Ceramic Matrix Comp’s. Polymer Matrix Comp’s
Classification of Synthetic Composites : Based on reinforcements

There are five basic types of composite materials: Fiber,

particle, flake, laminar or layered and filled composites.
 1. Fiber Composites
In fiber composites, the fibers reinforce along the line of
their length. Reinforcement may be mainly 1-D, 2-D or 3-D.
Figure shows the three basic types of fiber orientation.

 1-D gives maximum strength in

one direction.

 2-D gives strength in two

directions.

 Isotropic gives strength equally

in all directions.
 2. Particle Composites
 Particles usually reinforce a composite equally in all directions
(called isotropic). Plastics, cermets and metals are examples of
particles.
 Particles used to strengthen a matrix do not do so in the same way
as fibers. For one thing, particles are not directional like fibers.
Spread at random through out a matrix, particles tend to reinforce
in all directions equally.
 Cermets
(1) Oxide–Based cermets
(e.g. Combination of Al2O3 with Cr)
(2) Carbide–Based Cermets
(e.g. Tungsten–carbide, titanium–carbide)
 Metal–plastic particle composites
(e.g. Aluminum, iron & steel, copper particles)
 Metal–in–metal Particle Composites and
Dispersion Hardened Alloys
(e.g. Ceramic–oxide particles)
 3. Flake Composites
 Flakes, because of their shape, usually
reinforce in 2-D. Two common flake
materials are glass and mica. (Also
aluminum is used as metal flakes)
 Flake Composites

 A flake composite consists of thin, flat flakes

held together by a binder or placed in a matrix.
Almost all flake composite matrixes are plastic
resins. The most important flake materials are:

1. Aluminum
2. Mica
3. Glass
 Flake Composites

Basically, flakes will provide:

 Uniform mechanical properties in the plane of
the flakes
 Higher strength
 Higher flexural modulus
 Higher dielectric strength and heat resistance
 Better resistance to penetration by liquids and
vapor
 Lower cost
 4. Laminar Composites
 Laminar Composites are
composed of layers of materials
held together by matrix.

Laminar composites involve two or more layers

of the same or different materials. The layers
can be arranged in different directions to
give strength where needed. Speedboat hulls
are among the very many products of this
kind.
 Laminar Composites
We can divide laminar composites into three basic types:
 Unreinforced–layer composites
(1) All–Metal
(a) Plated and coated metals (electrogalvanized steel –
steel plated with zinc)
(b) Clad metals (aluminum–clad, copper–clad)
(c) Multilayer metal laminates (tungsten, beryllium)
(2) Metal–Nonmetal (metal with plastic, rubber, etc.)
(3) Nonmetal (glass–plastic laminates, etc.)

 Reinforced–layer composites (laminae and laminates)

 Combined composites (reinforced–plastic laminates well

bonded with steel, aluminum, copper, rubber, gold, etc.)
 Laminar Composites

 Like all composites laminar composites

aim at combining constituents to produce
properties that neither constituent alone
would have.

 In laminar composites (Un reinforced)

outer metal is not called a matrix but a
face. The inner metal, even if stronger, is
not called a reinforcement. It is called a
base.
 Laminar Composites

 A lamina (laminae) is any

arrangement of unidirectional
or woven fibers in a matrix.
Usually this arrangement is
flat, although it may be
curved, as in a shell.

 A laminate is a stack of
lamina arranged with their
main reinforcement in
different directions.
Laminate Sequence
 5. Filled Composites
 There are two types of filled composites. In
one, filler materials are added to a normal
composite result in strengthening the
composite and reducing weight. The second
type of filled composite consists of a skeletal
3-D matrix holding a second material. The
most widely used composites of this kind are
sandwich structures and honeycombs.
Sandwich Structure – Foam Core
Consists of a relatively thick core of low
density foam bonded on both faces to
thin sheets of a different material

Figure 9.7 - Laminar

composite structures: (b)
sandwich structure using foam
core
 Sandwich Structure – Honeycomb Core
 An alternative to foam core

 Either foam or honeycomb achieves

high strength-to-weight and
stiffness-to-weight ratios

Figure 9.7 - Laminar

composite structures: (c)
sandwich structure using
honeycomb core
 6.Combined Composites
 It is possible to combine several different materials
into a single composite. It is also possible to
combine several different composites into a single
product. A good example is a modern ski.
(combination of wood as natural fiber, and layers as
laminar composites)