COMPOSITE MATERIALS

Composite materials are those which are created

artificially by combining two or more materials which
usually have dissimilar characteristics.

or

Materials system composed of a combination of two or

more constituents that differ in form and chemical
composition and which are insoluble in each other.
Composite materials is formed when one or more
material distributed or re-inforced in a continuous
second phase called ‘matrix’.

The matrix phase surrounds the other phase which

is called the dispersoid or re-inforcement.
Ex: cement- concrete
FIBROUS COMPOSITES
 Generally there are two phases
 Fiber as a reinforcement
 Matrix as a binder
COMPOSITES
Can you think of any
examples of where composites
are used?
COMPOSITES
Composites can be found in:
-Boat hulls
-The aerospace industry (structural components
as well as engines and motors)
-Automotive parts (panels, frames, dashboards,
body repairs)
-Sinks, bathtubs, hot tubs, swimming pools
-Cement buildings, bridges
-Surfboards, snowboards, skis
-Golf clubs, fishing poles, hockey sticks
-Trees are technically composite materials,
plywood
-Electrical boxes, circuit boards, contacts
-Everywhere
Where are composites
used??????

CFRP – carbon
fiber reinforced
composite.

GFRP –
glass fiber
reinforced
composite
COMPOSITES IN INDUSTRY

 Engineering applications
 Aerospace
 Automobile
 Pressure vessel and pipes
 Any place where high performance materials are desired

Turret Shield Bullet proof

Industrial
Medical Table shields
Spring
www.composiflex.com
EXAMPLES OF NATURAL COMPOSITES

 Wood
 Cellulose Fibers
 Lignin Matrix
 Bones
 Collagen Fibers
 Mineral Matrix
• Some examples of man‐made composites

– Concrete: Particulate composite of aggregates

(limestone or granite), sand, cement and water
– Plywood: Several layers of wood veneer glued
together
– Fiberglass: Plastic matrix reinforced by glass fibers
– Cemets: Ceramic and metal composites
– Fibrous composites:Variety of fibers (glass, kevlar,
graphite, nylon, etc.) bound together by a
polymeric matrix
ADVANTAGES OF COMPOSITES
 Specific Strength and Stiffness
 Tailored Design

 Fatigue Life

 Dimensional Stability

 Corrosion Resistance

 Cost-Effective Fabrication
 Classification of composites
Composite materials can be classified in two ways

I. According to Base – Matrix material

Polymer matrix
Ceramic matrix
Metal-matrix

II. According to shape of reinforcement

Fibre/whiskers
Particulate
Laminate
I. According to Base – Matrix material

Polymer – Matrix Composites (PMCs)

Polymer-matrix composites (PMCs) consist of a polymer

resin as the matrix, with fibers as the reinforcement
medium.
These have excellent room temperature properties, ease of
fabrication, highly economical costs and aesthetic values.
Polymer matrices are often dispersed with the
re-informcement material in the shape of fibers
which are normally strong and have a higher
melting temperature.

Thermoplastic polymers and thermosetting

polymers are both used extensively as matrix
materials.
 Thermo plastic polymers Thermo setting polymers

They have long chain polymers held by They have 3D network of primary
secondary bonds bonds

Polymerization is linear Polymerization proceeds in all

directions

They soften when heated and harden They become permanently hard when
when cooled. Processes are totally heated and do not soften upon
reversible subsequent heating. Irreversible process

At high temperatures, these polmers At high temperature, the strong cross

liquify bcz of the breaking of seconday linked bonds are broken and leads to
bonding forces polymer degradation rather than
melting
Classifications of PMCs are discussed according to
reinforcement type (i.e.,glass, carbon, and aramid),
1. Glass Fiber–Reinforced Polymer (GFRP) Composites
2. Carbon Fiber–Reinforced Polymer (CFRP) Composites
Glass Fiber–Reinforced Polymer (GFRP) Composites:
• Fiberglass is simply a composite consisting of glass fibers, either
continuous or discontinuous, contained within a polymer matrix
• Glass is popular as a fiber reinforcement material for several
reasons:
1. It is easily drawn into high-strength fibers from the molten
state.
2. It is readily available
3. As a fiber it is relatively strong, and when embedded in a plastic
matrix
Many fiberglass applications are familiar: automotive and marine
bodies, plastic pipes,
2. Carbon Fiber–Reinforced Polymer (CFRP) Composites

• Carbon is a high-performance fiber material that is the most

commonly used reinforcement
in advanced (i.e., non fiberglass) polymer-matrix composites.
• The reasons for this are as follows:
1. Carbon fibers have the highest specific strength of all
reinforcing fiber materials.
2. They retain their high tensile modulus and high strength at
elevated temperatures;
3. At room temperature, carbon fibers are not affected by
moisture or a wide
variety of solvents, acids, and bases.
• Carbon-reinforced polymer composites are currently being used
extensively in sports ,pressure vessels, and aircraft structural
components—both military and commercial, fixed-wing and
helicopters
Ceramic Matric Composites (CMC)

Ceramic materials are very well known for their high temperature
properties as well as their resistance to oxidation. But they are very
brittle which limits their applications.
The fracture toughnesses of ceramics have been improved
significantly by the development of a new generation of ceramic-
matrix composites (CMCs)

Ceramic matrix materials used are :

Silicon nitride (Si3N4)
Silicon carbide (SiC)
Alumina (Al2O3)
Zirconium dioxide (ZrO2)
But it is fact that ceramics make better reinforcement materials than
matrix materials
Metal Matric Composites (MMC)

Here metals are alloys used as Matrix materials.

Metals used are usually ductile in nature and reinforced with
strong and low density materials of all shapes – fibers, whiskers
and particulate.

Such combination improves materials stiffness, abrasion

resistance, creep resistance, thermal conductivity and dimensional
stability.
Alloys of Al, Mg, Ti and Cu are generally employed as matrix
materials.

The reinforcement in the form of fibers, whiskers or particulates

are in MMC’s in the range of 10 and 60% by volume.
Popular reinforcement include C, SiC, Boron, Alumina

Ex: Al-alloy matrix with alumina & C fibres used in automobiles as engine
components.
II. According to shape of reinforcement
1. Fiber-Reinforced Composites
• Most fiber-reinforced composites provide improved strength and
other mechanical properties and strength-to-weight ratio .
• The characteristics of Fiber-Reinforced Composites are expressed
in terms of specific strength and specific modulus
• specific strength is the ratios of tensile strength to specific
gravity
• specific modulus is modulus of elasticity to specific gravity.
The matrix material acts as a medium to transfer the load to the
fibers, which carry most off the applied load. The matrix also
provides protection to fibers from external loads and atmosphere
.fiber-reinforced composites are sub classified by fiber length.
 FIBER ALIGNMENT

Adapted from Fig. 16.8,

Callister 7e.

aligned aligned random

continuous discontinuous
2. PARTICULATE COMPOSITE
• In this type, particles of varying shape and
size of one material is dispersed in a matrix
of second material

• For most of these composites, the particulate phase is harder and

stiffer than the matrix
• These reinforcing particles tend to restrain movement of the
matrix phase in the vicinity of each particle.
• In essence, the matrix transfers some of the applied stress to the
particles, which bear a fraction of the load.
Large-particle composite:

 Example of large-particle composite is concrete, which

is composed of cement (the matrix) and sand and gravel
(the particulates).
 Large-particle composites are used with all three
material types (metals, polymers, and ceramics).
Dispersion-strengthened composites:
 For dispersion-strengthened composites, particles
are normally much smaller, with diameters
between 0.01 and 0.1 μm (10 and 100 nm).
 The matrix bears the major portion of an applied
load, then small dispersed particles hinder or
impede the motion of dislocations.
 The dispersed phase may be metallic or
nonmetallic; oxide materials are often used
3.A Llaminar

AMINAR COMPOSITES
composite is composed of
two-dimensional sheets or panels that
have a preferred high-strength
direction, such as is found in wood and
continuous and aligned fiber–
reinforced plastics
 The layers are stacked and
subsequently cemented together such
that the orientation of the high-
strength direction varies with each
successive layer (Figure)
 For example, adjacent wood sheets
in plywood are aligned with the grain
direction at right angles to each other
 laminar composite has relatively high
strength in a number of directions in Figure The stacking of successive oriented
the two-dimensional plane fiber–reinforced layers for a laminar
composite
ROLE OF MATRIX, REINFORCEMENT,
INTERFACE IN COMPOSITE MATERIAL

Role of matrix
 Holds the fibers together.
 To transfer the load to the reinforcement
 Protects the fibers from environment.
 Distributes the loads evenly between fibers so that all fibers 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 fibers
Role of reinforcement
 to Carry the load in the composite system

 The role of the reinforcement in a composite

material is fundamentally one of increasing the
mechanical properties of the neat resin system
 To strengthen and stiffen the composite through
prevention of matrix deformation by mechanical
restraint.
 the reinforcement also serves to reduce the
density of the composite, thus enhancing
properties such as specific strength.
Role of interface:
 Via interface matrix transfer load to
reinforcement
 A weak interface results in low strength and
stiffness
 A strong interface result in high strength leads to
brittle failure
BEHAVIOR UNDER LOAD FOR
FIBERS & MATRIX
HYBRID COMPOSITE
 New fiber-reinforced composite is the hybrid, which is
obtained by using two or more different kinds of fibers in a
single matrix;
 In the most common system, both carbon and glass fibers
are incorporated into a polymeric resin.
 The carbon fibers are strong and relatively stiff and provide
a low-density reinforcement; however, they are expensive.
 Glass fibers are inexpensive and lack the stiffness of
carbon.
 The glass–carbon hybrid is stronger and tougher,
has a higher impact resistance, and may be
produced at a lower cost than either of the
comparable all-carbon or all-glass reinforced
plastics
 Principal applications for hybrid composites are
lightweight land, water, and air transport
structural components, sporting goods, and
lightweight orthopedic components
 COMMERCIALLY AVAILABLE
FORMS OF REINFORCEMENT
-Filament: a single thread like fiber

-Roving: a bundle of filaments wound to form a large

strand

-Chopped strand mat: assembled from chopped

filaments bound with a binder

-Continuous filament random mat: assembled from

continuous filaments bound with a binder

-Many varieties of woven fabrics: woven from

rovings
COMMERCIALLY AVAILABLE
FORMS OF REINFORCEMENT

Above Left: Roving

Above Right: Filaments
Right: Close up of a roving
COMMERCIALLY AVAILABLE
FORMS OF REINFORCEMENT

Random mat and woven fabric

(glass fibers)
 COMMERCIALLY AVAILABLE
FORMS OF REINFORCEMENT

Carbon fiber woven fabric

FUNDAMENTALS OF PRODUCTION OF
FIBER-REINFORCED COMPOSITES
1. Open Mould Processes
1. Hand lay-up
2. Bag moulding process
1. Pressure-bag moulding
3. Filament Winding
4. Spray-up process
2. Closed-mould process
1. Pultrusion process
2. Sheet-moulding compound process
 OPEN MOLD PROCESSES
1. Hand lay-up
Tapes and fabrics can also be placed in a die and formed by bag
molding. High-pressure gases or a vacuum are introduced to
force the individual plies together so that good bonding is
achieved during curing. Large polymer matrix components for
the skins of military aircraft have been produced by these
techniques.
3. Filament Winding
4. Spray-up process
 Fiberis chopped in a hand-held gun and fed
into a spray of catalyzed resin directed at the
mould.

 Thedeposited materials are left to cure under

standard atmospheric
II.Closed-mould process

1. Pultrusion
Process:
• Continuous-fiber rovings, or tows,are first impregnated with a thermosetting
resin;
• These are then pulled through a steel die that preforms to the desired shape
and also establishes the resin/fiber ratio.
• The stock then passes through a curing die that is precision machined so as to
impart the final shape;
• This die is also heated to initiate curing of the resin matrix. A pulling device
draws the stock through the dies and also determines the production speed.
• The cured product is cut on the desired length by the cut-off saw.
• Principal reinforcements are glass, carbon, and aramid fibers, normally added in
concentrations between 40 and 70 vol%. Commonly used matrix materials include
polyesters, vinyl esters, and epoxy resins.
2. SHEET-MOULDING COMPOUND(SMC)
PROCESS
Process:
 In this process, plastic resin paste is first deposited over a travelling
polyethylene sheet with the help of a filler.
 On top this resin paste, continuous strand fiber glass roving cut to
length is deposited
 Another layer of resin filler paste is added over this combination to
form a continuous sandwich of fiber glass and resin.
 The sandwich which is covered with poly-ethylene sheet on top as well
as at the bottom is compacted and rolled into package-sized rolls
Advantages:
1. SMC method is used to produce near net shape.
2. Rate of production is high.
3. It is a low cost high volume production technique with moderate
strength.
4. Part reproducibility is excellent.
Applications:
This technique is used for many application areas like automotive,
electrical, electronics, sanitary ware, furniture and other structural
components
FUNDAMENTAL OF PRODUCTION OF METAL-
MATRIX COMPOSITE
1. Foundry techniques
a. Sand casting
b. Die casting
c. Centrifugal casting
d. Squeeze casting
2. Powder metallurgy technique
3. Diffusion bonding
 1. Foundry techniques
a. Sand casting

Mechanical stirrer used for uniform dispersing

of reinforcement( fibres,particles) in base
matrix

(Molten metal)
b. Die casting

c. Centrifugal casting
 Die casting is a metal casting process that is
characterized by forcing molten metal under high
pressure into a mold cavity. The mold cavity is created
using two hardened tool steel dies which have been
machined into shape and work similarly to an injection
mold during the process
 Centrifugal casting, sometimes called rotocasting, is a
metal casting process that uses centrifugal force to
form cylindrical parts. This differs from most metal
casting processes, which use gravity or pressure to fill
the mold. In centrifugal casting, a permanent mold
made from steel, cast iron, or graphite is typically
used. However, the use of expendable sand molds is
also possible.
 STIR CASTING
 The simplest and the most cost effective method of liquid state
fabrication is Stir Casting.

 Stir Casting is a liquid state method of composite materials

fabrication, in which a dispersed phase (ceramic particles, short
fibers) is mixed with a molten matrix metal by means of mechanical
stirring.

 The liquid composite material is then cast by conventional casting

methods and may also be processed by conventional Metal forming
technologies.
STIR CASTING PROCESS
d. Squeeze casting
SQUEEZE CASTING INFILTRATION
2. Powder metallurgy
technique

Metal + fibres
powder
POWDER METALLURGY
Metal

Powder

Metal Product
ADVANTAGES, LIMITATIONS AND
APPLICATIONS OF COMPOSITE
MATERIALS
Advantages:
1. High strength to weight ratio (low density high tensile
strength) High creep resistance
2. High tensile strength at elevated temperatures
3. High toughness
4. Fatigue strength and creep is better
5. Generally perform better than steel or aluminum in
applications where cyclic loads are encountered leading
to potential fatigue failure (i.e. helicopter blades).
6. Impact loads or vibration – composites can be specially
formulated with high toughness and high damping to
reduce these load inputs.
7. Some composites can have much higher wear resistance
than metals.
8. Corrosion resistance
9. Dimensional changes due to temp changes can be much
less.
10. Anisotropic – bi-directional properties can be design
advantage (i.e. helicopter blades)
Disadvantages (or limitations):
1. Material costs
2. Fabrication/ manufacturing difficulties
3. Repair can be difficult
4. Wider range of variability (statistical spread)
5. Operating temperature can be an issue for
polymeric matrix . Less an issue for metal matrix .
6. Properties non-isotropic makes design difficult!
7. Inspection and testing typically more complex.
Applications
 Polymer-matrix composites with continuous fiber
reinforcement are widely used for lightweight structures,
such as airframes.
 Polymer-matrix composites with metal particles (e.g.,
silver particles) are used for electrical interconnections
 Rubber-matrix composites reinforced with carbon black
particles are used for automotive tires
 Cement-matrix composites in the form of concrete are
widely used for civil infrastructure
 Metal-matrix composites known as cermets (meaning
ceramic-metal combinations) that contain a low volume
fraction (e.g., 15%) of ceramic (e.g., tungsten carbide)
particles are used in cutting tools such as drills.
 Metal-matrix composites containing graphite flakes as the
filler are also used as self-lubricating piston cylinders for
automobile engines due to the lubricity of graphite.
Other applications
 Space craft: Antenna structures, Solar reflectors,
Satellite structures, Radar, Rocket engines, etc.
 Aircraft: Jet engines, Turbine blades, Turbine
shafts, Compressor blades, Airfoil surfaces, Wing
box structures, Fan blades, Flywheels, Engine
bay doors, Rotor shafts in helicopters, Helicopter
transmission structures, etc.
 Miscellaneous:
(1) Bearing materials, Pressure vessels, Abrasive
materials, Electrical machinery, Truss members,
Cutting tools, Electrical brushes, etc.
(2) Automobile: Engines, bodies, Piston, cylinder,
connecting rod, crankshafts, bearing materials,
etc.