ME 582 Advanced Materials Science

Chapter 1 Introduction to Composite Materials

Dr. Jan Gou Composite Materials Research Laboratory Department of Mechanical Engineering University of South Alabama, Mobile, AL 36688

ME 582 Advanced Materials Science Department of Mechanical Engineering

Dr. Jan Gou

Definition of Composite Materials

A composite is a structural material that consists of two or more combined constituents that are combined at a macroscopic level and are not soluble in each other Reinforcing phase: fibers, particles, or flakes Matrix phase: polymers, metals, ceramics

ME 582 Advanced Materials Science Department of Mechanical Engineering

Dr. Jan Gou

Fiber-Reinforced Composites

ME 582 Advanced Materials Science Department of Mechanical Engineering

Dr. Jan Gou

Fiber-Reinforced Composites (Contd)

ME 582 Advanced Materials Science Department of Mechanical Engineering

Dr. Jan Gou

Characteristics of Composite Materials

High specific strength and modulus, as well as high fatigue strength and fatigue damage tolerance Anisotropic Designable or tailorable materials for both microstructure and properties Production of both material and structure or component in a single operation - manufacturing flexible, net-shape, complex geometry Corrosion resistance and durable Other unique functional properties - damping, low CTE (coefficient of thermal expansion)

ME 582 Advanced Materials Science Department of Mechanical Engineering

Dr. Jan Gou

Specific Modulus
Axial Deflection

=
Mass

PL EA

M = AL
M= PL2 1 4 E/

Lightest beam for specified deflection under a specified load is one with the highest modulus E /
ME 582 Advanced Materials Science Department of Mechanical Engineering Dr. Jan Gou

Specific Modulus
Critical Load

Pcr =
Second Moment of Area

2 EI
L2

d4 I = 64

Mass of Rod

M =

d 2 L
4

2 L2 Pcr

1 E 1/ 2 /

1/ 2 Lightest beam for specific stiffness is one with the highest value of E /

ME 582 Advanced Materials Science Department of Mechanical Engineering

Dr. Jan Gou

Specific Modulus

ME 582 Advanced Materials Science Department of Mechanical Engineering

Dr. Jan Gou

Specific Modulus

ME 582 Advanced Materials Science Department of Mechanical Engineering

Dr. Jan Gou

Disadvantages of Composites
High cost of fabrication of composites Mechanical characterization of a composite structure is more complex than a metal structure Repair of composites is not a simple process compared to that for metals Composites do not have a high combination of strength and fracture toughness compared to metals Composites do not necessarily give higher performance in all the properties used for material selection: strength, toughness, formability, joinability, corrosion resistance, and affordability
ME 582 Advanced Materials Science Department of Mechanical Engineering Dr. Jan Gou

Fracture Toughness of Composites

ME 582 Advanced Materials Science Department of Mechanical Engineering

Dr. Jan Gou

Material Selection Parameters

ME 582 Advanced Materials Science Department of Mechanical Engineering

Dr. Jan Gou

Factors vs Mechanical Performance

Fiber Factors Length Orientation Shape Materials Matrix Factors Fiber-Matrix Interface Chemical bonding Natural roughness CTE of matrix Reaction bonding
ME 582 Advanced Materials Science Department of Mechanical Engineering Dr. Jan Gou

2000 U.S. Composites Shipments

Other- 3% Transport 32% Aircraft -1%

Appliance -5% Marine 11% Construction 20% Electrical 10% Consumer 7%

Corrosion 11%

Source: CFA (June 2000)

Est. 3.9 Billion Lbs of Shipments in 2000

ME 582 Advanced Materials Science Department of Mechanical Engineering

Dr. Jan Gou

Types of Composites
Particulate composites Flake composites Fiber composites Nanocomposites

ME 582 Advanced Materials Science Department of Mechanical Engineering

Dr. Jan Gou

Polymer Matrix Composites

Polymer matrix composites Polymer: epoxy, polyester, urethane Fiber: graphite, aramids, boron Drawbacks of PMCs Low operating temperature High coefficients of thermal High moisture expansion Low elastic properties Mechanical properties of PMCs
ME 582 Advanced Materials Science Department of Mechanical Engineering Dr. Jan Gou

Mechanical Properties of PMCs

ME 582 Advanced Materials Science Department of Mechanical Engineering

Dr. Jan Gou

Mechanical Properties of Fibers

ME 582 Advanced Materials Science Department of Mechanical Engineering

Dr. Jan Gou

Manufacturing of Glass Fibers

ME 582 Advanced Materials Science Department of Mechanical Engineering

Dr. Jan Gou

Manufacturing of Carbon Fibers

ME 582 Advanced Materials Science Department of Mechanical Engineering

Dr. Jan Gou

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 shear strength Determine damage tolerance of composites
Model of unidirectional composite

Determine in-plane shear strength Determine the processibility of composites Determine heat resistance of composites

ME 582 Advanced Materials Science Department of Mechanical Engineering

Dr. Jan Gou

Common Matrices in PMCs

ME 582 Advanced Materials Science Department of Mechanical Engineering

Dr. Jan Gou

Thermoplastics and Thermoset

ME 582 Advanced Materials Science Department of Mechanical Engineering

Dr. Jan Gou

Sheet Molding Compounds (SMC)

Matrix: polyester resin, vinyl ester resin Used for compression molding process SMC - R: randomly oriented discontinuous fibers SMC CR: containing a layer of unidirectional continuous fibers XMC: containing continuous fibers arranged in an X pattern

ME 582 Advanced Materials Science Department of Mechanical Engineering

Dr. Jan Gou

Manufacturing of SMC

ME 582 Advanced Materials Science Department of Mechanical Engineering

Dr. Jan Gou

Prepreg Manufacturing

ME 582 Advanced Materials Science Department of Mechanical Engineering

Dr. Jan Gou

Bag Molding Process/Autoclave Process

prepreg (B-stage resin)

ME 582 Advanced Materials Science Department of Mechanical Engineering Dr. Jan Gou

Filament Winding Process

ME 582 Advanced Materials Science Department of Mechanical Engineering

Dr. Jan Gou

Analysis of Laminated Composites

ME 582 Advanced Materials Science Department of Mechanical Engineering

Dr. Jan Gou

Hybrid Laminates
Interply hybrid laminates Intraply hybrid laminates Interply-intraply laminates Resin hybrid laminates

ME 582 Advanced Materials Science Department of Mechanical Engineering

Dr. Jan Gou