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    Basics of Composite Materials

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    andrw1987
    Composite materials are made from two or more constituent materials combined at a macroscopic level. The document discusses the basics of composite materials including definitions, types, components, fibers, matrices and manufacturing techniques. It provides details on common fibers like glass, carbon, aramid and matrices like polymers, metals and ceramics. The key advantages of composites are their high strength to weight ratio, design flexibility and corrosion resistance compared to other materials like metals.

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    Basics of Composite Materials

    Uploaded by

    andrw1987
    141 views47 pages
    Composite materials are made from two or more constituent materials combined at a macroscopic level. The document discusses the basics of composite materials including definitions, types, components, fibers, matrices and manufacturing techniques. It provides details on common fibers like glass, carbon, aramid and matrices like polymers, metals and ceramics. The key advantages of composites are their high strength to weight ratio, design flexibility and corrosion resistance compared to other materials like metals.

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    Composites

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    Composites

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    Composite materials are made from two or more constituent materials combined at a macroscopic level. The document discusses the basics of composite materials including definitions, types, components, fibers, matrices and manufacturing techniques. It provides details on common fibers like glass, carbon, aramid and matrices like polymers, metals and ceramics. The key advantages of composites are their high strength to weight ratio, design flexibility and corrosion resistance compared to other materials like metals.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    141 views47 pages

    Basics of Composite Materials

    Uploaded by

    andrw1987
    Composite materials are made from two or more constituent materials combined at a macroscopic level. The document discusses the basics of composite materials including definitions, types, components, fibers, matrices and manufacturing techniques. It provides details on common fibers like glass, carbon, aramid and matrices like polymers, metals and ceramics. The key advantages of composites are their high strength to weight ratio, design flexibility and corrosion resistance compared to other materials like metals.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 47

    Basics of Composite

    Materials

    What is a Composite?
    A Composite Material signifies that two or more materials are

    combined on a macroscopic scale to form a useful third material.

    Wood is a common example of a natural composite, combining


    cellulose fibre and lignin.
    Earliest known man made composites are Mud bricks. The
    combination of mud with straw gives the brick a good tear and
    squeeze resistance.

    Alloy Vs Composites
    Alloys also have the same definition as the composite
    material.
    Now how does a composite differ from an alloy?. When
    alloys are formed the individual components lose their
    individuality and they behave as a whole homogeneous
    structure.
    While Composites individual components retain their
    nature and look as a heterogeneous structure.

    Types of Composite Materials


    Fibrous Composite Materials
    Laminated Composite Materials (e.g. Laminated Glass)
    Particulate Composite Materials. (e.g. Concrete)

    Components
    The Basic Components which make up a composite are
    Reinforcements ( Fibres)
    Matrix

    Types of Fibres
    Glass

    Carbon

    Aramid (Kevlar)

    Boron

    Ceramic

    Metallic

    Types of Matrices
    Polymers
    Metals
    Ceramics

    Function of the Fiber


    Carry the load
    70 to 90% of load carried by fibers
    Provide structural properties to the composite
    Stiffness
    Strength
    Thermal stability
    Provide electrical insulation

    Function of the Matrix


    Binds the fibers together
    Provides rigidity and shape to the structure
    Isolates fibers to slow crack propagation
    Surface quality
    Corrosion and wear protection for fibers

    Fibres
    Glass Fibres:
    Glass is produced from silica sand, limestone, boric acid, and other
    elements.
    E-glass: Alumina-calcium-borosilicate glass
    S- glass: Magnesium alumino silicate glass
    Advantages
    Applicable to wide range of geometries and sizes, Seamless construction.
    Good strength and durability,
    Lower tooling costs, Increased design flexibility.
    Minimal maintenance &Corrosion resistant.

    Disadvantages:
    Mechanical properties are not as good as metals or other reinforcing fibres.

    Carbon Fibres:
    Types of graphite fibres include:
    Polyacrylonitrile (PAN)-Based fibres
    Pitch-Based fibres
    Rayon-Based fibres
    Advantages:
    Excellent strength & stiffness,
    Excellent specific strength and stiffness, and
    Corrosion resistant.
    Disadvantages
    Significantly more expensive than glass fibres.
    Brittle behaviour.

    Aramid Fibres: (Kevlar

    TM

    Para aramid fiber characterized by high tensile strength


    and modulus
    Advantages:
    Very high strength & stiffness,
    Very high specific strength & stiffness,
    Excellent impact resistance
    High toughness.
    Corrosion resistant.
    Disadvantages:
    Significantly more expensive than glass fibres, and
    Properties may be affected by environmental factors (e.g.

    Matrices
    Polymers

    The polymer matrices are the most commonly used and they
    offer good bonding characteristics when compared with other
    matrix types.
    In commercial usage these polymers matrices are called Resins.
    There are different types resins available.
    Some of the most used resins are
    Polyester
    Epoxy
    Phenolic

    Polyester Resin
    Polyester is a thermoset polymer that is formed
    from a condensation polymerization. Polyester has been
    widely used in commercial applications with fiberglass.
    Advantages:
    Low cost
    A wide assortment of di acids and diols can be used to
    give physical and chemical properties.
    Disadvantages:
    Poor temperature capabilities, Poor weather resistance
    Poor mechanical properties (stiffness and strength) as
    compared to advanced composites

    Epoxy Resin
    Epoxy is a thermoset polymer that forms a strong rigidly
    cross-linked network of polymer chains. Epoxy has been widely
    used in commercial applications with fiberglass, graphite, and
    aromatic fibres.
    Advantages
    Excellent adhesion
    Excellent mechanical properties (strength and stiffness),
    Excellent chemical resistance, Excellent weather resistance.
    Low shrinkage, Good fatigue strength.
    Good corrosion protection and Versatility in processing.

    Disadvantages
    Poor high temperature capabilities
    Uncured resin is toxic
    Poor handling properties (uncured)
    Relatively expensive.

    Phenolic resin
    Phenolic is a thermoset polymer with good high temperature
    properties. It is now being used as a composite resin with
    graphite, and aromatic fibres
    Advantages:
    Good mechanical properties (strength and stiffness),
    Good thermal properties with an ablative nature, and
    Good processability
    Disadvantages:
    Absorbs moisture easily,
    Brittle behaviour, and
    Relatively expensive (more than epoxies).

    Laminated Fibre Reinforced Composites


    The laminated fibre reinforced composites combine the
    laminated and fibrous composites to produce high strength
    and stiffness properties.
    These composites consists of stack of layers or sheets called
    lamina.
    The lamina are the building blocks which has fibres aligned
    in a matrix.
    The stacks of lamina are called a laminate which make up
    the composite.

    Sandwich Composites

    Sandwich panel is also a kind of layered composite. It


    consists of faces and core
    With increase in thickness of core, its stiffness increases
    as seen in the most common sandwich panel
    honeycomb.
    Faces:-They are formed by two strong outer sheets.
    Core:-Core is layer of less dense material.
    Honeycomb:-Structure which contain thin foils forming
    interlocked hexagonal cells with their axes oriented at
    right angles in the direction of face sheet.

    Manufacturing Techniques
    Some of the manufacturing methods of composites are
    Hand Lay up Method
    Vacuum bag Moulding Process
    Filament Winding Process
    Sheet Moulding Compound

    Hand Lay Up Process

    Advantages:
    low cost tools
    versatile: wide range of products
    Disadvantages:
    time consuming
    easy to form air bubbles and disorientation of fibers
    inconsistency

    Vacuum Bag Moulding Process

    Advantages:
    simple design
    any fiber/matrix combination
    ok with cheap mold material
    better quality for the cost
    Disadvantages:
    cannot be heated up too much
    breeder clothe has to be replaced frequently
    low pressure (760 mm Hg the most)
    slowest speed
    inconsistency

    Filament Winding Process


    Process by which continuous reinforcing fibers are
    accurately positioned in a predetermined pattern to form
    a shape (usually cylindrical).
    Use machine to wrap composite around mandrel
    Mandrel is then removed, leaving hollow composite part
    Angles generally set at -45,0,+45

    Advantages:
    using existing textile processes.
    quick, easy to handle package.
    parts can have huge size.
    Disadvantages:
    spinning speed is limited due to resin penetration and
    splashing, traveler speed and yarn breakage.
    curing by heat is not easy to apply.
    shape of the products limited (only cylindrical
    possible).

    Sheet Moulding Compound

    Sheet moulding compound (SMC) refers to both a


    material and a process for producing glass fibre
    reinforced polyester resin items.
    The material is typically composed of a filled,
    thermosetting resin and a chopped or continuous strand
    reinforcement of glass fibre
    The glass fibre is added to a resin mixture that is carried
    onto a plastic carrier film.
    After partial cure, the carrier films are removed. The
    sheet moulding material is cut into lengths and placed
    onto matched metal dies under heat and pressure

    Advantages
    High productivity thus inexpensive
    consistency
    Excellent part reproducibility.
    Minimum material scrap.
    Excellent design flexibility.
    Disadvantages
    low volume fraction.
    Only board can be made.

    Cure
    To irreversibly change the properties of a thermosetting
    resin by chemical reaction, i.e., condensation, ring,
    closure, or addition. Cure may be accomplished by
    addition of curing (cross-linking) agents, with or without
    heat.

    Oven Cure
    Once the layup is accomplished and
    the part is debulked, we can put it
    into a furnace to cure the resin.
    Typically the parts are instrumented
    with a thermocouple to track the
    temperature of the part in the oven.
    The temperature of the oven is
    increased until the thermocouple
    registers the correct curing
    temperature and then the part is
    soaked at temperature until it is
    cured.

    Autoclave
    Autoclave is a pressure vessel
    with pipework to allow a vacuum
    to be maintained in the bagged
    work piece.
    Temperature control is normally
    by gas- or electric-heating

    Advantages

    Light Weight- Composites are light in weight. Their


    lightness is important in automobiles and aircraft, for
    example, where less weight means better fuel efficiency
    High Strength- Composites can be designed to be far
    stronger than aluminium or steel. Metals are equally
    strong in all directions. But composites can be engineered
    and designed to be strong in a specific direction.
    Strength Related to Weight- Strength-to-weight ratio is a
    materials strength in relation to how much it weighs.
    Composite materials can be designed to be both strong
    and light.

    High-Impact Strength- Composites can be made to


    absorb impactsthe sudden force of a bullet, for
    instance, or the blast from an explosion.
    Design Flexibility- Composites can be moulded into
    complicated shapes more easily than most other
    materials. This gives designers the freedom to create
    almost any shape or form.
    Part Consolidation- A single piece made of composite
    materials can replace an entire assembly of metal parts.
    Nonconductive- Composites are nonconductive, meaning
    they do not conduct electricity.

    Low Thermal Conductivity- Composites are good


    insulatorsthey do not easily conduct heat or cold.
    Radar Transparent- Radar signals pass right through
    composites, a property that makes composites ideal
    materials for use anywhere radar equipment is operating,
    whether on the ground or in the air
    Corrosion Resistance- Composites resist damage from
    the weather and from harsh chemicals that can eat away
    at other materials

    Disadvantages
    High cost of raw materials and fabrication.
    Composites are more brittle than wrought metals and
    thus are more easily damaged.
    Transverse properties may be weak.
    Matrix is weak, therefore, low toughness.
    Reuse and disposal may be difficult.
    Inspection Methods are costly.

    Applications in Aerospace- Civil


    Airframes, Wing Spars, Fuel Tanks, Helicopter Rotor
    Blades, Engine Nacelles, Nose Cone & Landing Gear Doors
    Tunnel supports, Airport facilities such as runways
    Roads and bridge structures , Marine and offshore
    structures
    Concrete slabs
    Architectural features and structures such as exterior
    walls, handrails, etc.

    In Sports
    Canoes and Kayaks
    Vaulting Pole
    Golf & Polo rods
    Archery equipment
    Hand gliders
    Wind surfer boards

    Chemical & Nuclear Reactors


    Double-wall FRP vessels with an early warning system for
    leakage detection
    Underground storage tanks
    pumps and blowers, columns.
    As Cladding material and Control Rods

    Marine & Electrical


    Propellers vanes, Fans and Blowers
    Gear cases
    Valves and Strainers
    Structures for overhead transmission lines for railway
    Power line insulators
    Lightning poles

    Automotive
    Fibre Glass/Epoxy Springs for Heavy Trucks and Trailers
    Rocker Arm Covers, Suspension Arms, Wheels and Engine Shrouds
    Filament-Wound Fuel Tanks
    Electrical Vehicle Body Components and Assembly Units
    Valve Guides

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