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P. K. Sinha
P. K. Sinha
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CHAPTER-1
INTRODUCTION
1.1 NATURAL AND MAN-MADE COMPOSITES
A composite is a material that is formed by combining two or more materials to
achieve some superior properties. Almost all the materials which we see around us are
composites. Some of them like woods, bones, stones, etc. are natural composites, as they
are either grown in nature or developed by natural processes. Wood is a fibrous material
consisting of thread-like hollow elongated organic cellulose that normally constitutes
about 60-70% of wood of which approximately 30-40% is crystalline, insoluble in water,
and the rest is amorphous and soluble in water. Cellulose fibres are flexible but possess
high strength. The more closely packed cellulose provides higher density and higher
strength.
The walls of these hollow elongated cells are the primary load-bearing
components of trees and plants. When the trees and plants are live, the load acting on a
particular portion (e.g., a branch) directly influences the growth of cellulose in the cell
walls located there and thereby reinforces that part of the branch, which experiences more
forces. This self-strengthening mechanism is something unique that can also be observed
in the case of live bones. Bones contain short and soft collagen fibres i.e., inorganic
calcium carbonate fibres dispersed in a mineral matrix called apatite. The fibres usually
grow and get oriented in the direction of load. Human and animal skeletons are the basic
structural frameworks that support various types of static and dynamic loads. Tooth is a
special type of bone consisting of a flexible core and the hard enamel surface. The
compressive strength of tooth varies through the thickness. The outer enamel is the
strongest with ultimate compressive strength as high as 700MPa. Tooth seems to have
piezoelectric properties i.e., reinforcing cells are formed with the application of pressure.
The most remarkable features of woods and bones are that the low density, strong and
stiff fibres are embedded in a low density matrix resulting in a strong, stiff and
lightweight composite (Table 1.1). It is therefore no wonder that early development of
aero-planes should make use of woods as one of the primary structural materials, and
about two hundred million years ago, huge flying amphibians, pterendons and pterosaurs,
with wing spans of 8-15 m , could soar from the mountains like the presentday hang-
Materials
Density
Tensile modulus
Tensile strength
Kg/m3
GPa
MPa
Cotton
1540
1.1
400
Flax
1550
780
Jute
850
35
600
Coir
1150
200
Pineapple leaf
1440
65
1200
Sisal
810
46
700
Banana
1350
15
650
Asbestos
3200
186
5860
Bone
1870
28
140
Ivory
1850
17.5
220
Balsa
130
3.5
24
Spruce
470
11
90
Birch
650
16.5
Oak
690
13
Bamboo
900
20.6
Fibres
Composites
137
90
193
Woods, stones and clays formed the primary structural materials for building
shelters. Natural fibres like straws from grass plants and fibrous leaves were used as
roofing materials. Stone axes, daggers, spears with wooden handles, wooden bows,
fishing nets woven with vegetable fibers, jewelleries and decorative articles made out of
horns, bones, teeth, semiprecious stones, minerals, etc. were but a few examples that
illustrate how mankind, in early days, made use of those materials. The limitations
experienced in using these materials led to search for better materials to obtain a more
efficient material with better properties. This, in turn, laid the foundation for development
of man-made composite materials.
The most striking example of an early man-made composite is the strawreinforced clay which molded the civilization since prehistoric times. Egyptians, several
hundred years B.C., were known to reinforce the clay like deposits of the Nile Valley
with grass plant fibres to make sun baked mud bricks that were used in making temple
walls, tombs and houses. The watchtowers of the far western Great Wall of China were
supposed to have been built with straw-reinforced bricks during the Han Dynasty (about
200 years B.C.). The natural fibre reinforced clay, even to-day continues to be one of the
primary housing materials in the rural sectors of many third world countries.
The other classic examples are the laminated wood furniture used by early
Egyptians (1500 B.C.), in which high quality wood veneers are bonded to the surfaces of
cheaper woods. The origin of paper which made use of plant fibres can be traced back to
China (108 A.D.). The bows used by the warriors under the Mongolian Chief Djingiz
Chan (1200 A.D.) were believed to be made with the adhesive bonded laminated
composite consisting of buffalo or anti-lope horns, wood, silk and ox-neck tendons.
These laminated composite bows could deliver arrows with an effective shoot in range of
about 740 m.
Potteries and hydraulic cement mortars are some of the earliest examples of
ceramic composites. The cloissone ware of ancient China is also a striking example of
wire reinforced ceramics. Fine metallic wires were first shaped into attractive designs
which were then covered with colored clays and baked. In subsequent years, fine metallic
wires of various types were cast with different metal and ceramic matrices and were
utilized in diverse applications. Several other matrix materials such as natural gums and
resins, rubbers, bitumen, shellac, etc. were also popular. Naturally occurring fibres such
as those from plants (cotton, flux, hemp, etc.), animals (wool, fur and silk) and minerals
(asbestos) were in much demand. The high value textiles woven with fine gold and silver
threads received the patronage from the royalty and the rich all over the world. The
intricate, artful gold thread embroidery reached its zenith during the Mughal period in the
Indian subcontinent. The glass fibres were manufactured more than 2000 years ago in
Rome and Mesopotamia and were abundantly used in decoration of flower vases and
glass wares in those days.
The twentieth century has noticed the birth and proliferation of a whole gamut of
new materials that have further consolidated the foundation of modern composites.
Numerous synthetic resins, metallic alloys and ceramic matrices with superior physical,
thermal and mechanical properties have been developed. Fibres of very small diameter
(<10m) have been drawn from almost all materials. They are much stronger and stiffer
than the same material in bulk form. The strength and stiffness properties have been
found to increase dramatically, when whiskers (i.e., single crystal fibers) are grown from
some of these materials. Figure1.1 illustrates the specific tensile strength and the specific
tensile modulus properties are obtained by dividing the strength (M Pa) and modulus
(G Pa) by either the density (kg m-3) or the specific gravity of the material. Because of the
superior mechanical properties of fibers, the use of fibers as reinforcements started
gaining momentum during the twentieth century. The aerospace industries took the lead
in using fiber reinforced laminated plastics to replace several metallic parts. The fibres
like glass, carbon, boron and Kevlar, and plastics such as phenolics, epoxies and
polyesters caught the imagination of composite designers. One major advantage of using
fibre reinforced plastics (FRP) instead of metals is that they invariably lead to a weight
efficient design in view of their higher specific modulus and strength properties (Table
1.2).
Composites, due to their heterogeneous composition, provide unlimited
possibilities of deriving any characteristic material behavior. This unique flexibility in
design tailoring plus other attributes like ease of manufacturing, especially molding to
any shape with polymer composites, repairability, corrosion resistance, durability,
adaptability, cost effectiveness, etc. have attracted the attention of many users in several
engineering and other disciplines. Every industry is now vying with each other to make
the best use of composites. One can now notice the application of composites in many
disciplines starting from sports goods to space vehicles. This worldwide interest during
the last four decades has led to the prolific advancement in the field of composite
materials and structures. Several high performance polymers have now been developed.
Substantial progress has been made in the development of stronger and stiffer fibres,
metal and ceramic matrix composites, manufacturing and machining processes, quality
control and nondestructive evaluation techniques, test methods as well as design and
analysis methodology. The modern man-made composites have now firmly established as
the future material and are destined to dominate the material scenario right through the
twenty-first century.
tensile
tensile
modulus strength
S
E
G Pa
Specific
compressive
strength
Xt
Xc
E/S
Xt/S
Xc/S
M Pa
M Pa
G Pa
M Pa
M Pa
2.0
40
1650
1400
20.00
825.0
700.0
CFRP
1.6
140
1450
1050
87.50
906.3
656.3
KFRP
1.5
90
1650
300
60.00
1100.0
200.0
Steel
7.8
206
400-2500
400-2500
26.40
50-320
50-320
Ti alloy
4.5
103
360-1400
360-1400
22.90
80-310
80-310
Al alloy
2.8
69
55-700
55-700
24.60
20-250
20-250
Mg alloy
1.8
47
150-300
150-300
25.00
83-166
83-166
Beryllium
1.8
303
400
400
168-33
222
222
Metals
Chicago in 1912. Almost all biplanes and monoplanes, with very few exceptions, were
built of wood during the first quarter of the twentieth century. Lighter woods like balsa,
poplar, spruce, tulip, etc. were more popular. The five-seater Lockheed Vega (first flight
in 1927) also had highly polished, smooth, streamlined fuselage made of strips of spruce
wood bonded together with resin. The Vegas were considered to be the precursor of the
modern transport airplane and had the distinction of successfully completing many major
flights such as crossing the American continent non-stop from Los Angels to New York,
over-flying the Atlantic, encircling the globe and succeeding in several other long distant
flights and races. Soaring planes, in those days, also had highly polished thin plywood
fuselages.
The thirties and forties noticed a gradual shift from wood to aluminium alloy
construction. With the increase in the size and speed of airplanes, the strength and
stiffness requirements for a given weight could not be met from wooden construction.
Several new structural features, e.g., skin-stringer construction, shear webs, etc. were
introduced. The aerospace grade aluminium alloys were made available. Two important
airplanes Northrop Alpha and Boeing Monomail, which were forerunners in the
development of several other aircraft, had aluminium alloy monocoque fuselage and a
wood wing. These aircraft were introduced in 1930, although they were not the first to
use metals. The switch over to light aluminium alloys in aircraft construction was no
doubt, a major step in search for a lightweight design. The trend continued till fifties, by
which almost all types of airplanes were of all-metal design.
However, the limitations of aluminium alloys could be assessed as early as fifties
with the speed of the aircraft increasing sharply (significantly more than the speed of
sound), the demand for a more weight optimized performance, the fuel-efficient design
and so on. The aluminium was stretched to its maximum limit. The search for newer and
better materials was the only alternative. Continuous glass fibres, which were
commercially available since thirties, are found to be very strong, durable, creaseless,
non-flamable and insensitive to weathering. The glass fibres coated with resin can be
easily moulded to any complex curved shape, especially that of a wing root and fuselage
intersection and can be laid layer wise with fibres aligned in a desired direction as in the
case of the three-layered wood fuselage of Le Monocoque. Fibreglass fabrics were
successfully used in a series of Todai LBS gliders in Japan during the mid-fifties. Todai
LBS-1 had spoilers made from fiberglass fabrics. Todai LBS-2 had a wood wing and a
sandwich monocoque fuselage whose wall consisted of a balsa wood core sandwiched
between two glass fibre reinforced composite face skins. The wing skin of another
important glider, the Phoenix (first flight in 1957), developed in Germany was a
sandwich with fiberglass-polyester faces and balsa wood core. The other successful glider
SB-6, first flown in 1961, had a glass fibre-epoxy shell and a glass fibre composite-balsa
sandwich box spar. The remarkable feature of all these gliders is that they exhibited
superior flight performance and thus became the trend-setters in the use of glass fibre
reinforced plastics.
Glass fibres are strong, but not stiff enough to use them in high sped aircraft. The
search for stiffer fibres to make fibre reinforced composite started in the fifties in several
countries. The laboratory scale production of high-strength carbon fibres by Royal
Aircraft Establishment, Farnborough, U.K. was reported in 1952. In USA, Union Carbide
developed high-modulus continuous carbon fibres in 1958. High-strength graphite fibres
were developed at the Government Industrial Research Institute of Osaka, Japan in 1959.
Before the end of sixties the commercial production of carbon fibres (PAN based) started
in full scale. Very high modulus boron fibres were also introduced during this time. High
strength, low density organic fibres, Kevlar 49, were also marketed by Dupont, USA
during early seventies. A host of synthetic resins, especially structural grade epoxy resins,
were also commercially available. All these advanced materials provided the muchneeded alternatives to less efficient aluminium alloy and fiberglass composites. The
switch-over from the aluminium and GFRP to advanced composites in airframe
construction was, however, very slow at the initial stage (Fig. 1.2). It started with the F14 fighter and the F-111 fighter bomber around 1972, but in the period of about two and a
half decades, there were quite a few airplanes, in which almost all structures are made of
composites (Table 1.3). Similar trend in material uses can be observed in the
development of helicopters as well. As early as 1959-60, the Vetrol Company, now
Boeing Helicopters, developed helicopter rotor blades with glass-epoxy faces and
aluminium honeycomb core. In course of time several structural parts such as horizontal
stabilizer, vertical pylon, tail cone, canopies, fuselage, floor board, rotor hub and landing
gears were developed with various composites, which later culminated in the
development of the all composite helicopter, Boeing Model 360 which was flight tested
in 1987.
The manufacturers of passenger aircraft soon realized the significance of using
composites in the airframe structure. CFRP, KFRP and hybrid composites were
extensively used throughout the wing, fuselage and tailplane sections of Boeing 767.
Although the application of composites in civilian aircraft is relatively less, this trend is
likely to change by the turn of the twenty-first century with the introduction of supersonic
civil transports. Some of the future transport planes may fly at a very high speed (Mach
2-5). Significant advancement has been made in several high technology areas such as
supersonic V/STOL flights, lightweight air superiority fighters with thrust vectoring,
supersonic interceptors and bombers with high Mach number, advanced lightweight
helicopters with tilt rotors, aerospace planes and hypersonic vehicles with multi-mode
trans atmospheric cruise capability such as take-off and landing with a turbine engine,
accelerating to Mach number 10-12 with a Scramjet and achieving an orbital velocity
with a rocket engine. The composite materials will provide an increased number of
choices to meet the tight weight budget and the critical performance level for all these
advanced flight vehicles.
Vehicles
Components
Composites
Sailplanes
SB-10
CFRP
All composite
CFRP
Stabilator
BFRP
SB-11, SB-12
Ventus, Nimbus,
AS-W22
Aeroplanes
F-14
F-15, F-16
BFRP
Speed brakes
CFRP
A-4
Flap, Stabilator
CFRP
F-5
Leading edge
CFRP
Vulcan
Airbrakes
CFRP
Mirage 2000
Rudder
AV-8B
Boron/carbon/epoxy
Front fuselage
CFRP
Rafale
Wing structure
CFRP
Boeing 757
&767
CFRP
A 310-300
Fin box
CFRP
All composite
CFRP
Voyager
All composite
CFRP
Starship
All composite
CFRP
Airbus, Concorde,
Delta 2000,
Brake discs
Carbon/carbon
DC-10
Aft pylon
Boron/aluminium
C-5A
Wing box
SiC/aluminium
F-111
Fuselge segment
Falcon 900
Boron/aluminium
Rockets and
Space Vehicles
Tactical
Quartz/polyimide
Missiles
fairing, Fins
Carbon/polyimide
Rocket cases
KFRP, GFRP
Tomahawk
Borosic/titanium
PSLV
Polaris,
Minuteman,
Poseidon,
Trident
10
KFRP
ARIANE
Hubble Space
CFRP
Graphite/6061 Al
Telescope
INTELSAT
Antennas,
Voyager
CFRP
CFRP sandwich
Boom
CFRP
CFRP
support structure
Dichroic subreflector
KFRP
INSAT,
ARABSAT, ITALSAT Antenne reflectors
CFRP
OLYMPUS
EUTELSAT
Dual-grided reflectors
TDF-1
EURECA
Micro-gravity spacecraft
CFRP
CFRP
Boron/aluminium
11
vanes and shafts of several aeroengines are now either employing or contemplating to use
in the near future metal matrix composites with boron, borsic, boron carbide, silicon
carbides or tungsten fibres and aluminium, titanium, nickel and super alloy (e.g. NiCrAly
or FeCrAly) matrices. S-glass, quartz
And carbon fibre reinforced polyimides have recently been used on radomes and fins
operating at high temperatures for short and long duration, because polyimides have high
temperature strength retention properties compared to epoxies and phenolics. Carboncarbon composites have been successfully employed in the brake discs of aircraft, rocket
nozzles and several other components operating in extreme thermal environments.
The material menu for rockets, missiles, satellite launch vehicles, satellites and
other space vehicles is quite extensive and diverse. The trend is to design some of the
upper stage structural components like payload structures, satellite frame works and
central cylindrical shells, solar panel wings, solar booms, antennas, optical structures,
thermal shields, fairings, motor cases and nozzles, propellant tanks, pressure vessels, etc.
with composite materials to derive the maximum weight benefit. All space vehicles of
recent origin have several composite structural systems. CFRP is the obvious choice
because of its excellent thermo-mechanical properties, i.e., high specific stiffness and
strength, higher thermal conductivity and lower coefficient of thermal expansion. The
future large space stations are likely to be built with CFRP. Although BFRP has several
positive features, it is mainly used for stiffening purposes. Both GFRP and KFRP are
favoured for design of pressurized systems for their superiority in strength and costeffectiveness. Beryllium, although not a composite, possesses highly favourable
properties (Table 1.2) but it is sparingly used due to safety hazards, especially during
fabrication. The examples of space applications of composites are too many. One of the
early major application is the graphite-epoxy mesh grid off-set parabolic antenna
reflector developed by Hughes Aircraft Company for the Canadian ANIK satellite which
was launched in 1972. The European Remote Sensing Satellite ERS-I has several
composite parts plus a large 10m long metallised graphite-epoxy radar antenna array. The
Voyager spacecraft contains a large 3.7m diameter CFRP parabolic antenna reflector.
The fairing of ARIANE 4 is a graphite composite stiffened shell structure of maximum
4m diameter and 8.6m height. A few other typical examples are listed earlier in Table
12
13
cost. But, in many applications, GFRP and KFRP may be cheaper considering the
cumulative cost. The low structural weight will have direct bearing in lowering the cost
of supporting skeletal structures and foundation. Moreover, ease of fabrication and
erection, low handling and transportation cost, less wear and corrosion, simpler
maintenance and repairing procedures, non-magnetic properties, integrity and durability
as well as modular construction will cumulatively reduce the cost in the long run. The
Living Environment house, developed by GE plastics in 1989, is an illustrative example
of the multipurpose use of composites in a building.
1.3.2 Automotive Engineering
Feasibility studies were carried out, since early seventies, to explore the
possibilities of using composites in the exterior body panels, frameworks/chassis,
bumpers, drive shafts, suspension systems, wheels, steering wheel columns and
instrument panels of automotive vehicles. Ford Motor Co. experimented with the design
and development of a composite rear floor pan for an Escort model using three different
composites: a vinyl-ester-based SMC and XMC and a glass fibre reinforced
prolypropylene sheet material. Analytical studies, static and dynamic tests, durability
tests and noise tests demonstrated the feasibility of design and development of a highly
curved composite automotive part. A composite GM heavy truck frame, developed by the
Convair Division of General Dynamics in 1979, using graphite and Kevlar fibres (2:1 by
parts) and epoxy resin (32% by wt) not only performed satisfactorily but reduce the
weight by 62% in comparison to steel for the same strength and stiffness. The hybrid
glass/carbon fibre composite drive shafts, introduced around 1982 in Mazdas, provided
more weight savings, lower maintenance cost, reduced level of noise and vibration and
higher efficiency compared to their metal counterparts. The more recent pickup truck
GMT-400 (1988 model) carries a composite driveshaft that is pultruded around a 0.2cm
thick and 10cm diameter aluminium tube. The composite driver shaft is 60% lighter than
the original steel shaft and possesses superior dampening and torsional properties.
Chevrolet Corvette models carry filament wound composite leaf springs (monoleaf) in
both rear suspension (1081) and front suspension (1984). These springs were later
introduced during 1985 on the GM Chevrolet Astro van and Safari van. Fibre glass
reinforced polypropylene bumper beams were introduced on Chevrolet Corvette Ford and
14
GM passenger cars (1987 models). Other important applications of composites were the
rear axle for Volkswagen Auto-2000, Filament wound steering wheels for Audi models
and composite wheels of Pontiac sports cars. Composites are recognized as the most
appropriate materials for the corrosion resistant, lightweight, fast and fuel efficient
modern automobiles, for which aerodynamics constitute the primary design
considerations. All major automotive components like space frames, exterior and interior
body panels, instrument panel assemblies, power plants, power trains, drive trains, brake
and steering systems, etc. are now being fabricated with a wide variety of composites that
include polymer, metal and ceramic matrix composites. The latter two composites will be
of significance in heated engine components and brake pads. The pistons and connecting
rods of modern diesel and IC engines are invariably made of composites with alumina
fibres and aluminium or magnesium alloy matrices. The Ford`s probe V concept car is a
classical example of multiple applications of composites in an automobile car. The
present trend is to use composites even in the design of large size tankers, trailers,
delivery vans and passenger vehicles.
15
The light artificial limbs and external bracing systems made of CFRP provide the
required strength, stiffness and stability in addition to lightness. Carbon fibres are
medically biocompatible. Composites made with carbon fibres and biocompatible metals
and polymers have been found to be suitable for a number of applications in
orthopaedics. A carboncarbon composite hip joint with an aluminium oxide head has
performed
satisfactorily.
Matrices
such
as
polyethylene,
polysulfone
and
polyaryletherketone reinforced with carbon fibres are also being used to produce
orthopaedic implants.
Composites also have extensive uses in electrical and electronic systems. The
performance characteristics of CFRP antennas are excellent due to very low surface
distortion. Composite antenna dishes are much lighter compared to metallic dishes.
Leadless ceramic chip carriers are reinforced with Kevlar or Kevlar-glass coweave
polyimides to reduce the incidence of solder joint microcracking due to stresses induced
by thermal cycling. The stress level is reduced by matching the low coefficient of
thermal expansion of ceramic chip carriers with that of tailored composites.
Composites are, now-a-days, preferred to other materials in fabrication of several
important sports accessories. A light CFRP golf shaft gives the optimum flexural and
torsional strength and stiffness properties in terms of accuracy and the distance travelled
by the ball. All graphite and graphite hybrid composite archery bows and arrows enhance
arrow speed with a flattened trajectory and increased efficiency. The reduction in weight
of a CFRP bobsleigh permits ballast to be added in the nose of the sleigh and thereby
improves the aerodynamic characteristics due to the change in the position of the centre
of gravity with respect to the centre of aerodynamic pressure. There are several other
interesting composite leisure time items such as skis, tennis and badminton rackets,
fishing rods, vaulting poles, hockey sticks, surf boards, and the list is likely to be endless
in the twenty-first century. The day is not far when common utility goods will be made
with composites. A few such examples are illustrated in Figs.1.5.
16
1.5 BIBLIGRAPHY
1. N.J.Hoff, Innovation in Aircraft Structures-Fifty years Ago and Today, AIAA
Paper No. 84-0840,1984.
2. R.J. Schliekelmann, A Soft and Hard Future - A Look into Past and Future
Developments of Structural Materials, AIAA International Annual Meeting on Global
Technology 2000, Baltimore, 1980.
3. S.M. Lee (Ed.), International Encyclopedia of Composites, Vols.1-6, VCH
Publishers, New York 1990-1991.
4. J.W. Weeton, D.M. Peters and K.L. Thomas (Eds.) Engineer`s
Guide to
1.6 EXERCISE
1. What are the special features of a structural composite? Compare between
natural and man-made structural composites.
2. Why composites are favoured in engineering applications? Write a brief note
on their uses in various engineering disciplines.
17
18
19
20
21
22
23
CHAPTER-2
COMPOSITE MATERIALS
2.1 INTRODUCTION
From this chapter onwards we restrict our attention primarily to man-made
modern composites that are used in structural applications. The main constituents of
structural composites are the reinforcements and the matrix. The reinforcements, which
are stronger and stiffer, are dispersed in a comparatively less strong and stiff matrix
material. The reinforcements share the major load and in some cases, especially when a
composite consists of fibre reinforcements dispersed in a weak matrix (e.g., carbon/epoxy
composite), the fibres carry almost all the load. The strength and stiffness of such
composites are, therefore, controlled by the strength and stiffness of constituent fibres.
The matrix also shares the load when there is not much difference between the strength
and stiffness properties of reinforcements and matrices (e.g., SiC/Titanium composite).
However, the primary task of a matrix is to act as a medium of load transfer between one
reinforcement to the other. It also holds the reinforcements together. In that regard, the
matrix plays a very vital role. Besides, the matrix may considerably influence the hygral,
thermal, electrical, magnetic and several other properties of a composite. For example, to
obtain a good conducting composite with SiC fibres one may choose an aluminium
matrix rather than a titanium matrix. It may be noted that both the SiC fibres and the
titanium matrix possess very poor thermal conductivities.
The classifications of composites are commonly based on either the forms of
reinforcements or the matrices used. There are two major forms of reinforcements: fibres
(including whiskers) and particles (having various shapes and sizes). Accordingly, there
are two broad classes of composites fibre reinforced composites and particle reinforced
composites (or simply particulate composites). On the other hand, there are three
important groups of matrices, namely, polymers, metals (and their alloys) and ceramics.
The composites made using these matrices are classifies as polymer matrix composites
(or polymer composites), metal matrix composites and ceramic matrix composites.
24
Composites are also grouped in several other ways. One important class of composites is
termed as laminar composites. They are also called laminated composites or laminates. A
laminate usually consists of two or more layers of planar composites in which each layer
(also called lamina or ply) may be of the same or different materials. Similarly, a
sandwich laminate is a composite construction in which a metallic or composite core
layer is sandwiched between two metallic or composite face layers. The composite face
layers may also be in the form of laminates. Laminated and sandwich composite
structures are very strong and stiff, and are commonly recommended for lightweight
structural applications.
2.2 REINFORCEMENTS
2.2.1 Fibres
Fibres constitute the main bulk of reinforcements that are used in making
structural composites. A fibre is defined as a material that has the minimum 1/d ratio
equal to 10:1, where 1 is the length of the fibre and d is its minimum lateral dimension.
The lateral dimension d (which is the diameter in the case of a circular fibre) is assumed
to be less than 254 m. The diameter of fibres used in structural composites normally
varies from 5m to 140m. A filament is a continuous fibre with the l/d ratio equal to
infinity. A whisker is a single crystal, but has the form of a fibre.
Common low density fibres are manufactured from lighter materials especially
those based on elements with low atomic number (e.g., H, Be, B, C, N, O, Al, Si, etc.).
The cross-section of a fibre may be circular, for example as in the cases of glass, boron
and Kevlar fibres, but some fibres may have regular prismatic cross-sections (e.g.,
whiskers) or arbitrary cross-sections (e.g., PAN, rayon and special pitch based carbon
fibres). The irregularity in the cross-section may introduce anisotropy in the fibre. The
typical microstructural morphology of common fibres are shown in Fig.2.1.
From the micro-structure point of view, fibres can be either amorphous (glass),
polycrystalline (carbon, boron, alumina, etc.) or single crystals (silicon carbide, alumina,
beryllium and other whiskers). The strength and stiffness properties of a fibre are
25
significantly higher compared to those of the bulk material from which the fibre is
formed. Most of the common fibres are brittle in nature. The tensile strength of bulk
brittle material is considerably lower than the theoretical strength, as it is controlled by
the shape and size of a flaw that the bulk material may contain. As the diameter of a fibre
is very small, a flaw, it may contain, must be smaller than the fibre diameter. The smaller
flaw size, in turn, reduces the criticality of the flaw and thereby the tensile strength is
enhanced. For example, the tensile strength of an ordinary glass (bulk) may be as low as
100-200 MPa, but that of a S-glass fibre may be as high as 5000 MPa. However, the
tensile strength of a perfect glass fibre, based on intermolecular forces, is 10350 MPa.
Further, the orientation of crystallites along the fibre direction also helps considerably in
improving the strength properties. A whisker, being a single crystal, is not prone to
crystal defects unlike polycrystalline fibres and provides very high strength and stiffness
properties. The tensile strength and tensile modulus of a graphite whisker are as high as
25000 MPa and 1050 GPa, respectively. These values are quite significant compared to
those of commercial fibres. The typical longitudinal tensile properties of a commercially
available PAN based T300 fibre are 2415 MPa (strength) and 220 GPa (modulus).
Typical thermomechanical and thermal properties of common fibres are listed in Tables
2.1 and 2.2, respectively.
Both inorganic and organic fibres are used in making structural composites.
Inorganic fibres (including ceramic fibres) such as glass, boron, carbon, silicon carbide,
silica, alumina, etc. are most commonly used. The structural grade organic fibres are
comparatively very few in number. Aramid fibres are the most popular organic fibres.
Another recent addition is a high strength polyethylene fibre (Spectra 900) which has a
very low density and excellent impact resistant properties. The carbon fibres may also be
grouped with organic fibres, although they are more often considered as ceramic
(inorganic) fibres. Inorganic fibres in general are strong, stiff, thermally stable and
insensitive to moisture. They exhibit good fatigue resistant properties, but low energy
absorption characteristics. Organic fibres, on the other hand, are cheaper, lighter and
more flexible. They possess high strength and better impact resistant properties.
26
Tensile
strength MPa
Tensile
modulus GPa
Diameter
m
Glass
2550
3450-5000
69-84
7-14
Boron
2200-2700
2750-3600
400
50-200
Carbon
1500-2000
2000-5600
180-500
6-8
Kevlar
1390
2750-3000
80-130
10-12
Polyethelyne
970
2590
117
38
Silica (SiO2)
2200
5800
72
35
Boron carbide
(B4C)
2350
2690
425
102
Boron nitride
1910
1380
90
6.9
Silicon
(SiC)
2800
4500
480
10-12
TiB2
4480
105
510
TiC
4900
1540
450
Zirconium oxide
4840
2070
345
Borsic(SiC/B/W)
2770
2930
470
107-145
Alumina(Al2O3)
3150
2070
210
17
Alumina FP
3710
1380
345
15-25
Steel
7800
4140
210
127
Tungsten
19300
3170
390
361
Beryllium
1830
1300
240
127
Molybdenum
1020
660
320
127
Quartz whisker
2200
4135
76
Fe whisker
7800
13,800
310
127
SiC whisker
3200
21,000
840
0.5-10
Al2O3 whisker
4000
20,700
427
0.5-10
BeO whisker
2851
13,100
345
10-30
Fibre Material
carbide
27
Density kg/m3
Tensile
strength MPa
Tensile
modulus GPa
Diameter
m
B4C whisker
2519
13,790
483
Si3N4 whisker
3183
13,790
379
1-10
Graphite whisker
2100
20,800
1000
Fibre Material
Melting point
0
C
Heat
Capacity
kJ/(kg.K)
Thermal
conductivity
W/(mK)
Coefficient of thermal
expansion 10-6 m/mK
Glass
840
0.71
13
Boron
2000
1.30
38
Carbon
3650
0.92
1003
-1.0
Kelvar 49
250
1.05
2.94
-4.0
SiC
2690
1.2
16
4.3
Steel
1575
0.5
29
13.3
Tungsten
3400
0.1
168
4.5
Beryllium
1280
1.9
150
11.5
Molybdenum
2620
0.3
145
4.9
Fe whisker
1540
0.5
29
13.3
Al2O3 whisker
2040
0.6
24
7.7
Quartz Whisker
1650
0.963
10
0.54
Organic fibres as well as glass, silica, quartz and carbon fibres are commercially
available in the form of strands, tows or yarns. A strand (or end) is a collection of
filaments. A tow (or roving) consists of several ends or strands. A yarn is a twisted
strand. Some twist is preferred for compactness and for making a composite with higher
fibre content. However, an excessive twist should be avoided, as that may not permit the
matrix to penetrate and wet all the fibres. These fibres are also used to make woven
rovings and woven fabrics (clothes). The weave styles in the fabrics may be
unidirectional (uniaxial), bidirectional (biaxial 2D and biaxial 3D) and multidirectional
28
(multiaxial). In a uniaxial fabric wrap fibres are yarns that are laid along the roll. Fill/pick
fibres, which constitute only a small percentage of the wrap fibres, are placed in the weft
direction which is transverse to the roll direction. The weaving design methodology and
weaving techniques, in most cases, adapt similar procedures that are followed in textile
technology. A few typical weave styles are illustrated in Figs. 2.2 and 2.3. Commercial
woven rovings are made with a simple plain weave style, whereas fabrics for carboncarbon composites may adopt complex multidirectional weaving patterns. Hybrid fabrics
may also be produced by mixing of various fibres in the warp and weft directions. Woven
rovings and fabrics are quite often preimpregnated with resin to make prepregs that are
convenient to use in the fabrication of composite parts.
Glass Fibres
Glass was first made by man in 3000 BC in Asia Minor. Continuous glass fibres
were known to be used for decorative purposes in ancient times in Syria and Venice. The
industrial manufacturing of glass fibres started in 1930`s for use in filters and insulations.
Glass fibres currently comprise more than 90% of fibres used in polymer composites.
There are five major types of glass used to make glass fibres. These are A glass (high
alkali), C glass (chemical), D glass (low dielectric constant), E glass (electrical) and S
glass (high strength), out of which the last two types, due to their superior mechanical
properties, are most widely used in composite roofings, pressure vessels, containers,
tanks, pipes, etc.
E glass is a low alkali, aluminium borosilicate glass and is based on a mixture of
alumina, boric acid, calcium carbonate and magnesia. S-glass is based on a mixture of
silica, alumina and magnesia. For the manufacture of glass fibres, glass is premixed and
formed into glass marbles or beads. The glass marbles or beads are then melt, and the
molten glass is gravity fed, under a controlled temperature, through a platinum bushing
containing a large number of very small orifices. The melt vitrifies within the bushing,
and the filaments are simultaneously cooled and drawn rapidly to a small diameter.
Figure 2.4 presents a schematic view of a fibre drawing process. The surfaces of drawn
glass fibres are normally treated with appropriate sizing materials to promote adhesion
29
with the resin matrix used, to facilitate weaving without causing mechanical damage to
the fibre or to improve certain properties like, toughness and impact resistance. The
cross-section of glass fibre is circular in nature and the diameter is usually in the range of
7-14 m. A glass fibre exhibits isotropic properties. Glass fibres are cheap, nonmagnetic,
x-ray transparent, chemically inert, biocompatible, insensitive to moisture and
temperature as well as possess high specific strength (strength to density ratio). However,
a long duration loading under certain environmental conditions, may reduce the load
carrying capacity of fibres by about 25%. This behaviour is known as static fatigue.
Silica Fibres
The silica (Si02) content of silica fibres ranges from 95 to 99.4% and is usually
much higher compared to that of glass fibres. The glass fibres contain only 55 to 75%
silica. The silica fibres are produced by treating glass fibres with acids so as to remove all
impurities. A quartz fibre is a ultra-pure silica fibre. Quartz fibres are made from natural
quartz crystals, in which the silica content is as high as 99.95%. There are a few other
methods for producing high silica or quartz fibres. In one method, a polymer of silicon
alkoxide is spun using a sol-gel process and subsequent heating of the fibre to 10000c
yields a 99.999% pure quartz fibre. Silica and quartz fibres have superior thermal
properties compared to glass fibres. They have extremely low thermal conductivities and
thermal expansion coefficients. They can withstand extreme changes in thermal
environments. They can be heated to a very high temperature without causing any
damage. These properties make them ideal materials for application in highly heated
structures such as thermal shields, nose cones, rocket nozzles, exit cones, etc.
Boron Fibres
Boron fibres with consistent and good mechanical properties were first
manufactured in the 1960`s. Boron is a multiphase fibre. A boron fibre is produced by
depositing boron on a thin substrate by a chemical vapour deposition process. Substrates,
which are thin filaments, usually made of tungsten or carbon. The substrate (of dia.8-
30
12m) is fed in a plating chamber containing a mixture of hydrogen and boron trichloride
and is electrically heated (Fig. 2.5). The boron is deposited in an amorphous form on the
surface of the substrate filament due to the chemical reaction as given by
2BCl3 + 2H2 2B + 6HCl
The thickness of the deposited boron depends on the rate at which the substrate is passed
through the plating chamber. The boron coated fibre is normally fed to successive plating
chambers to increase the diameter of the fibre. The boron fibres are often treated
chemically to remove surface defects, thermally to reduce residual stresses or by
providing thin coatings (SiC, B4C or BN) to increase oxidization resistance and to make
compatible with metal matrices.
The boron fibre is marketed as a single filament. The boron filaments are now
available in diameters 50m, 100m, 125m,140m and 200m. The boron fibre with a
tungsten substrate is costlier than that with a carbon substrate. A carbon substrate also
reduces the density of the fibre. Boron fibres are usually impregnated with a resin to form
tapes, as they are too stiff to weave. Boron fibres exhibit excellent stiffness properties,
because of which they are used for stiffening of structural parts in aerospace applications.
Their tensile strength is also quite good. The thermal properties are, however, in the
intermediate range, although the melting point temperature is on the higher side.
tungsten substrate). It is cheaper and lighter. No reaction takes place between the
deposited silicon carbide and the carbon substrate at a high temperature. The tensile
strength is also on the higher side. The tensile strength and tensile modulus of a SiC
whisker is 21000 MPa and 840GPa, respectively. SiC whiskers are grown by combining
silicon and carbon at 1200-15000C under special conditions.
A boron carbide vapour deposited mantle on a tungsten filament substrate can be
formed using mixture of boron trichloride and methane or carboranes. A boron carbide
fibre can also be produced by heating carbon fibres in a chamber containing boron halide
vapour. The melting point of a boron carbide fibre is 24500C, and the fibre retains proper
ties at a temperature higher than 10000C.
Alumina Fibres
The commercial grade alumina fibre developed by Du Pont is known as alumina
FP (polycrystalline alumina) fibre. Alumina FP fibres are compatible with both metal and
resin matrices. These fibres possess a high melting point temperature of 20400C. They
also withstand temperatures up to 10000C without loss of strength and stiffness
properties. They exhibit high compressive strengths, when they are set in a matrix.
Typical longitudinal compressive strengths of alumina FP/epoxy composites vary from
2275 to 2413 MPa. Alumina whiskers exhibit the tensile strength of 20700 MPa and the
tensile modulus of 427 GPa.
Carbon Fibres
Carbon fibres are also commonly known as graphite fibres, although there are
some basic differences between the two types. Graphitization takes place at a much
higher temperature compared to the temperature at which carbonization takes place. The
carbon content in the graphite fibre is also higher and is usually more than 99%. The
manufacture of carbon fibres in the laboratory scale started in the early fifties. However,
carbon fibres were made commercially available only during mid-sixties. They are made
after oxidizing and carbonizing the organic textile fibre precursors at high temperatures.
32
There are three common types of precursors: polyacrylonitrile (PAN), rayon and
petroleum pitch. A typical fibre fabrication process based on a precursor is shown in Fig.
2.6. The molecular orientation already present in a precursor is formed along the fibre
axis. Carbonization takes place at lower temperature (at about 10000C). The carbonized
fibre is then treated at higher temperature to facilitate the graphitization process. The
degree of graphitization can be enhanced by raising the temperature further. Highmodulus PAN and Rayon based graphite fibres need as high as 25000C for proper
graphitization. High strength PAN-based carbon fibres are treated at about 15000C for
required carbonization. The carbon fibre microstructural morphology changes
considerably with the precursor used (Fig.2.1). This also affects the fibre-matrix interface
characteristics. The fibres in general exhibit anisotropic behaviour. The average
diameters of commercial fibres range from 6-8m.
Carbon fibres are produced in a variety of tensile strengths and tensile moduli.
They are accordingly designated as ultrahigh, very high, high or intermediate modulus
and high strength. The tensile strength and tensile modulus of carbon fibres may be as
high as 5600 MPa and 500 GPa, respectively. Typical properties of some high modulus
and high strength fibres are presented in Table 2.3. Carbon fibres have many other
positive attributes, for which they are most popular in aerospace applications. They can
withstand extremely high temperatures without loss of much strength and stiffness. The
thermal conductivity is high and at the same time the coefficient of thermal expansion is
almost negligible. These thermal characteristics make them outstanding candidate
materials for high temperature applications. Further, carbon fibres are non-magnetic, xray transparent, chemically inert, bio-compatible and insensitive to moisture to a great
extent.
Carbon fibres are much costlier compared to glass and other organic fibres. Their
application is, therefore, limited to strategic structural components, expensive sport goods
and biological implants.
33
Type
Density
Tensile strength
Tensile modulus
Kg/m3
MPa
GPa
M40
1800
2740
390
M46
1900
2350
450
M50
1900
2450
490
T40
1800
5650
280
T75
1830
2620
545
T300
1770
3240
231
T400
1800
4500
250
T500
1800
5600
241
T800
1800
5600
290
1800
2240-2410
690-827
Aramid Fibres
These are aromatic polyamide fibres. These are based on polymers formed by
condensation of aromatic diacid derivatives with aromatic diamines. Kevlar is the trade
mark for the commercially available aramid fibres marketed by Du Pont first in the early
seventies. There are three types of Kevlar fibres: Kevlar, Kevlar 49 and Kevlar 29.
Kevlar 49 and Kevlar 29 fibres posses the same strength, but Kevlar 29 has the two-third
of the tensile modulus of Kevlar 49. Kevlar 29 is used for reinforcing rubber cordage and
belting. Kevlar is similar to Kevlar 49, but is designed for tyre reinforcement. Kevlar 49
fibres are commonly termed as Kevlar fibres and find extensive uses in pressure vessels,
motor cases and other structures where strength is the major design criterion. The
diameter of Kevlar fibres range from 8-12m.
Kevlar fibres, being organic in composition, are susceptible to hygral and thermal
environments. They are easily attacked by alkalis and acids. Each fibre is fibrillar in
nature and consists of several long, stiff fibrils (aligned along the fibre axis) embedded in
34
a softer matrix. Because of this microstructural morphology (Fig.2.1), Kevlar fibres are
very weak in compression (due to buckling of fibrils), but exhibit good impact resistance.
They are cheaper, non-magnetic, x-ray transparent and bio-compatible and resistant to
flame, organic solvents, fuels and lubricants.
2.2.2
Particulates
Particulates of various shapes and sizes are used as reinforcing particles. The
shapes vary from a simple sphere (e.g., glass beads) to a complex polyhedron (e.g.,
crystals). The size ranges from a few microns to several hundred microns. Particles of
various inorganic and organic materials are employed to make particulate composites.
However, they should be compatible with the matrix system used. Materials like talc,
clay, mica, calcium carbonate, calcium sulphate, calcium silicate, titanium oxide, wood
dust, sand, silica, alumina, asbestos, glass beads, metal flakes, metal powder, carbon
powder, ceramic grains and several polymeric particles are normally used. Besides
strengthening the composite, particles also serve other purposes. They act as additives to
modify the creep, impact, hygral, thermal, electrical, chemical and magnetic properties as
well as wear resistance, flammability and such other properties of the composite. They
may as well be utilized as fillers to change the matrix content and density of the
composite. The strength, stiffness and other properties of the composite are dependent on
the shape, size, distribution and blends of various particles in a given matrix and also on
the particle-matrix interface condition. Depending on the composite`s end use, the
volume content of the reinforcement may go up to 40-50%, or more.
Short fibres are discontinuous fibres and may also be treated as particles with
cylindrical shapes. Flakes/platelets are also commonly used. They are less expensive than
short fibres, and can be aligned to obtain improved in plane directional properties
compared to those of short fibres. Metal flakes (say, aluminium) can be used to improve
the thermal and electrical conductivity of the composite, whereas mica flakes can be
added to the matrix to increase the resistivity.
Solid glass microspheres, silicate-base hollow microspheres and ceramic
aluminosilicate macrospheres are used in reinforcing polymer matrices. The particle
diameter for solid glass microspheres ranges from 5 to 50m, whereas for hollow
35
microspheres it ranges from 10 to 300m. The spherical shape of these particles allows a
uniform distribution of stresses through the matrix. The composite also behaves like an
isotropic material. For a given volume, the surface required to wet with a resin is
minimum for a sphere. This permits to provide a smooth surface finish to a product
without increasing the resin content. One positive advantage with hollow microspheres is
that the weight can be considerably reduced without compromising on the strength of a
composite. The density of hollow microspheres ranges from 150 to 380 kg/m3 and is
considerably lower than that of the polymer matrix. The composite formed with hollow
microspheres is, therefore, lighter than the matrix itself.
Metal and ceramic matrices are also very commonly reinforced with particulates.
Aluminium alloys reinforced with silicon carbide particles are found to exhibit higher
strengths and stiffnesses. The tensile strength and Young`s modulus of the aluminium
alloy AA2124-T6 matrix reinforced with the silicon carbide particles (volume content by
40%) are observed to be about 690 MPa and 150 GPa, respectively. Ceramic grains of
borides, carbides, oxides, nitrides, silicides, etc. are dispersed in metal matrix to produce
a host of particulate composites known as cermets. Some cermets, if properly made, may
possess low density, but at the same time, may exhibit good thermomechanical
properties.
2.3
matrix materials, namely, metals and ceramics. Almost all reinforcements, inorganic and
organic, can be used with polymers to produce a wide range of reinforced plastics or
polymer composites. Polymers are particularly attractive due to several reasons. The
densities of polymers are usually very low. Polymers are easily processable. The
processing and curing temperature are normally in the lower range, and in some cases,
the ambient temperature will suffice. This brings down the manufacturing cost
substantially due to a low energy input. Further, polymers constitute a wide class of
organic materials, each having a distinct characteristic feature. This makes them all the
more attractive from the point of view of developing composites having different
36
37
Polyamideimide
Polyetherimide
Polysulfone
Polypheny
lene
sulfide
Density, kg/m3
1300
1400
1270
1240
1340
Tensile strength,
MPa
104
138
115
70
76
Tensile modulus,
GPa
4.21
4.48
3.38
2.48
3.31
Poissons ratio
0.35
0.35
0.35
0.35
0.35
Coefficient of
thermal expansion,
10-6m/m K
56
50
86.40
88
Maximum service
temperature, K
630
490
490
565
Properties
to their relatively stiff, linear chains and high molecular weight. They are also strong and
stiff and exhibit good creep resistant properties. They are relatively tougher and less
sensitve to moisture. The structures of these resins are illustrated in Fig. 2.7. All resins
are found to contain a high proportion of aromatic rings that are linked by a stable
heteroatom or group (-CO-, SO2-, -O-, etc.). This provides a high degree of chain rigidity
and thereby results in a higher Tg. In addition, the low aliphatic hydrogen (C-H) content
enhances the thermal stability of all these resins at high temperatures. PEEK and
polyphenylene sulfide are essentially crystalline polymers, and other resins shown in
Table 2.4 are amorphous. PEEK has received considerable attention since its inception.
The rigid rings, connected by fairly chemically inert groups (-o- and c-) make PEEK
highly crystalline. The melting point and chemical resistance of PEEK are also
considerably enhanced. PEEK has a Tg of 1430C and a melting point of 3320C. It is
soluble only in concentrated sulphuric acid. The processing temperature ranges 3004000C. The moisture absorption limit is very low. The fracture toughness is
comparatively higher. All these features of PEEK make it a highly attractive
thermoplastic resin for application in reinforced composites. Graphite/PEEK composite
prepregs are commercially available. Polysulfones reinforced with glass, aramid and
carbon fibres have also found several applications.
38
2.3.2
Thermosets
Thermoset polymers are formed from relatively low molecular weight precursor
Epoxies
Polyesters
Phenolics
Polyimides
1100-1400
1200
1200-1300
1400
35-100
50-60
50-60
100-130
1.5-3.5
2-3
5-11
3-4
Poissons ratio
0.35
0.35
0.35
0.35
Coefficient of thermal
expansion, 10-6m/mK
50-70
40-60
40-80
30-40
Service temperature, K
300-370
330-350
440-470
550-750
Density, kg/m3
The most commonly used thermosets are epoxy, polyester and phenolic resins, among
which polyster resins are most widely used in various common engineering goods and
composite applications. However, epoxy resins constitute the major group of thermoset
resins used in composite structures and adhesives, as they are stronger and stiffer.
Phenolic resins are rich in carbon and possess good thermal properties and are normally
used in high temperature applications especially as an ablative material in thermal
protection systems. Silicone, bismaleimide, polyimide, polybenzimidazol, etc. are in fact,
high temperature polymers that can perform at higher temperature ranging from 2004500C. The structures of some thermosetting resins are illustrated in Fig. 2.8.
39
ethers and amines which are the major sources for epoxies in composite applications.
The common epoxy is synthesized by condensing epichlorohydrin with bisphenol A in
the presence of sodium hydroxide. Several other hydroxyl-containing compounds can
replace bisphenol A. A wide variety or special purpose resins can thus be prepared.
Some aerospace grade epoxy systems are based on an aromatic amine (glycidyl
amines) instead of a phenol to increase the epoxy functionality leading to high crosslink density in the cured resin. Epoxy resins are cured using suitable curing agents or
appropriate catalysts. The major curing agents are aliphatic amines, aromatic
polyamines and polyanhydrides. Curing is the processs of reaction (ionic reaction,
usually polyadditions) between the epoxide and the curing agent in which many
epoxide groups are formed. Aliphatic amines are relatively strong bases and therefore
react with aromatic amines to achieve cure at room temperature. The reaction is highly
exothermic, and the pot life is shorter. This epoxy resin is useful for contact moulding,
but not for prepregging and filament winding. Aromatic polyamines are normally
solids and require high temperature (100-1500C) for mixing and curing. Anhydrides
need higher thermal exposure (150-2000C) for a longer duration (8-16 hours) for
proper curing. The reaction is low exothermic, but the pot life is longer. Both
polyamines and anhydrides are suitable for prepreg manufacturing and filament
winding. These epoxy resins are characterized by comparatively high thermal stability
and chemical resistance. Catalysts can also be used along with curing agents to
accelerate the curing process. Catalytic agents that are often used as curing agents to
promote homopolymerisation of epoxide groups may be Lewis acids or bases. The
commonly used catalytic curing agent is boron trifluoride blocked with ethyl amine (a
typical Lewis acid). It is also used as a catalyst with aromatic amines to accelerate
curing at a temperature of 150-2000C. Lewis bases are normally used as accelerators
with anahydrides. Both Lewis acids and bases provide long pot lives.
40
41
42
Uses
Aerospace
CFRP
BFRP
KFRP
GFRP
Structural
GFRP
Sports
GFRP/CFRP
43
Reinforcements
C, Be, SiO2, B, SiC, Al2O3, Steel,
B4C, Al3Ni, Mo, W, ZrO2
B, SiC, Mo, SiO2, Be,ZrO2
C, Be, Al2O3,SiC, Si3N4, steel, W,
Mo, B
C, B, glass, Al2O3
B, ZrO2
Fe, Steel, B, Al2O3, W, SiO2,ZrO2
C,B, Al2O3, E-glass
44
Density
kg/m3
Tensile
strength
MPa
Tensile
modulus
GPa
Coefficient
thermal
expansion
10-6m/mk
Thermal
conduct-vity
W/(mk)
Heat
capa-city
KJ/
(kg.k)
Melting
point
0
C
AA6061
2800
310
70
23.4
171
0.96
590
Nickel
8900
760
210
13.3
62
0.46
1440
Ti-6AL-4V
4400
1170
110
9.5
0.59
1650
Magnesium 1700
280
40
26
100
1.00
570
Steel
7800
2070
206
13.3
29
0.46
1460
Copper
8900
340
120
17.6
391
0.38
1080
because of its low melting point. Titanium and nickel can be used at a service
temperature of up to 1000-11000C. There are several systems such as engine components
which are exposed to high level of temperature. Titanium and nickel composites are ideal
for such situations, as they retain useful properties at 1000-11000C. Ti-6AL-4V is the
commonly used titanium matrix material. The other alloys of titanium include A-40Ti, A70Ti, etc. Nickel matrices are comprised of a series of Ni-Cr-W-Al-Ti alloys. Super
alloys, NiCrAlY and FeCrAlY, are also used as matrices because of their high oxidation
resistance properties. Molybdenum is a high temperature matrix and fibre material. Iron
and steel matrices are cheaper and can be used at high temperatures, if the weight is not
the major concern. Figure 2.9 exhibits a fractograph of the Al2O3 fibre reinforced Mg
alloy ZM21 composite. A scanning electron micrograph of the Al2O3 fibre reinforced AA
2014 composite is shown in Fig. 2.10.
The high temperature applications of metal matrix composites are listed in Table
2.9. The material cost is the major problem that currently limits their uses, otherwise
45
most of the metallic structural parts can be replaced with metal matrix composite parts to
gain advantages.
Fig.2.9
Fig.2.10
Composites
MMCs
Applications
Aeroengine Blades, Combustion Chamber, Thrust
Chamber, Nozzle Throat, Exit Nozzle, Engine
Valves, Fins.
CMCs
Carbon-Carbon
46
as it, quite often, leads to catastrophic failure. For this reason ceramics are not considered
as dependable structural materials. But such limitations may not exist with ceramic
matrix composites, as suitable reinforcements may help them to achieve desirable
mechanical properties including toughness. The ceramic matrices are usually glass, glass
ceramics (lithium aluminosilicates), carbides (SiC), nitrides (SiN4, BN), oxides (Al2O3,
Zr2O3, Cr2O3, Y2O3, CaO, ThO2) and borides (ZrB2, TiB2). The reinforcements which are
normally high temperature inorganic materials including ceramics, may be in the form of
particles, flakes, whiskers and fibres. The commonly used fibres are carbon, silicon
carbide, silica and alumina. The current resurgence in the research and development of
ceramic matrix composites is due to their resistance to wear, creep, low and high cycle
fatigue, corrosion and impact combined with high specific strength at high temperatures.
The cutting rate of an alumina-SiC whisker cutting tool is ten times higher than that of
conventional tools. The use of ceramic composites in aero-engine and automotive engine
components can reduce the weight and thereby enhance the engine performance with
higher thrust to weight ratios due to high specific strength at high temperatures.
Automotive engines exhibit greater efficiency because of their low weight, better
performance at high operating temperatures and longer life time due to excellent
resistance to heat and wear. Several high temperature applications of ceramic matrix
composites are presented in Table 2.9.
Carbon-carbon composites are the most important class of ceramic matrix
composites that can withstand temperatures as high as 30000C. They consist of carbon
fibres distributed in a carbon matrix. They are prepared by pyrolysis of polymer
impregnated carbon fibre fabrics and preforms under pressure or by chemical vapour
deposition of carbon or graphite. The polymers used are of three types: thermosets
(furfurals, phenolics), thermoplastic pitches (coal tar based and petroleum based) and
carbon-rich vapours (hydrocarbons such as methane, propane, acetylene, benzene).
Phenolic resins are more commonly used in the manufacturing process of carbon-carbon
composites. The phenolic resin impregnated carbon fibre preforms, on pyrolysis, converts
the phenolic resin to a high proportion of amorphous carbon char. The composite material
is found to be porous after the first pyrolysis. It is further impregnated with the phenolic
resin and pyrolised, usually under vacuum and pressure, and the process is repeated
47
several times to reduce the void content and realize the optimum density of the material.
The major advantage of carbon-carbon composite is that various fabrics and shapes of
preforms with multidirectional fibre alignments can be impregnated with resins and
pyrolised to yield a wide class of one directional (1D), two directional (2D), three
directional (3D) and multidirectional composite blocks of various shapes and sizes, which
can be machined to produce the desired dimensions. Excellent wear resistance, higher
coefficient of friction with the rise of temperature, high thermal conductivity, low thermal
expansivity and high temperature resistance make them useful materials in high
temperature applications. In absence of oxygen, carbon-carbon composites can withstand
very high temperatures (30000C or more) for prolonged periods. They are also used in
prosthetics due to excellent biocompatibility.
lamina are kept at the middle. Unless it is specified, it is normally assumed that all the
laminae in a laminate possess the same thickness. A cross-ply laminate consists of only
00 and 900 laminae. An angle-ply laminate, on the other hand, contains only laminae.
A laminate may be considered symmetric, antisymmetric or unsymmetric, in case there
exists, with respect to the middle surface, any symmetry, antisymmetry or unsymmetry,
respectively. Figures 2.13 and 2.14 illustrate several cross-ply and angle-ply laminates. It
should be further noted that a [ (00/900)n ] laminate is an antisymmetric cross-ply laminate
consisting of n numbers of repeating two-layered (00/900) cross-ply laminates. The total
number of laminae in a [ (00/900)n ] laminate is 2n. However, a [ (00/900)ns ] laminate is a
symmetric cross-ply laminate. It has symmetry about the midsurface of the laminate. The
top half of the laminate contains n number of repeating of repeating two-layered (00/900)
cross-ply laminates. The bottom half consists of n number of two-layered (900/00) crossply laminates so that the symmetry about the mid-surface is maintained. Note that the
subscript `s` stands for symmetry and the number of laminae in a [ (00/900)ns] laminate is
4n. The laminates containing repeating () angle-plies can also be identified in a similar
way.
A general unsymmetric laminate may contain 00 laminae, 900 laminae and/or
laminae stacked in an arbitrary manner. For example, [ (00)4 / (900)2], [(900)2/ (300)2] and
[00/900/300/600] are all general unsymmetric laminates. An unsymmetry may also be
introduced by stacking laminae made of different composites. A [00c/900g /00k] laminate
consists of a top layer of 00 carbon fibre reinforced composite, a middle layer of 900 glass
fibre reinforced composite and bottom layer of 00 Kevlar fibre reinforced composite and
is an unsymmetric cross-ply hybrid laminate. Various such hybrid laminates can be
prepared for practical applications choosing various combinations of layers of metallic
materials, polymer composites, metal-matrix composites and ceramic composites. The
ARALL is a hybrid laminate consisting of alternate layers of aramid/epoxy composite
and aluminium alloys. Aramid epoxy composites are commonly combined with carbon
epoxy composites to make carbon-kevlar hybrid composites to obtain a cost effective
composite with superior compressive and impact resistant properties. Kevlar fibres are
inexpensive compared to carbon fibres and are effective in resisting the impact forces.
49
2.7 BIBLIOGRAPHY
1. J.W. Weeton, D.M. Peters and K.L. Thomas (Eds.), Engineer`s Guide to
Composite Materials, American Society for Metals, Metals Park, Ohio, 1987.
2. S.M. Lee (Ed.), Encyclopedia of Composites, Vols. 1-4, VCH Publications, New
York, 1990-1991.
3. R. Smith, Resin Systems, in Processing and Fabrication Technology, Delware
Composites Design Encyclopedia, Vol.3 (Eds. M.G. Bader, W. Smith, A.B.
Isham, J.A. Rolston and A.B. Metzner), Technomic Publishing Co., Inc.
Lancaster, 1990, p.15.
4. B.C. Hoskin and A.A. Baker (Eds.), Composite Materials for Aircraft Structure,
AIAA Education Series, American Institute of Aeronautics and Astronautics Inc.,
New York, 1986.
2.8 EXERCISES
1. Why fibres are preferred to other reinforcements ? What are whiskers ? Describe
how fibres are fabricated using vapour deposition processes.
2. What are carbon-carbon composites and how they are produced ?
Why they are recommended for high temperature applications ?
3. Write a note on metal matrix composites.
4. Write a note on ceramic matrix composites.
5. Describe the characteristics of a couple of thermosets and thermoplastics that are
used for making composites for aerospace applications.
6. Why Kevlar fibres are recommended for strength and impact based structural
designs? What are the basic differences between organic and other fibres ?
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59
CHAPTER 3
COMPOSITE MANUFACTURING
3.1 INTRODUCTION
Manufacturing is a very broad discipline and encompasses several processes such
as fabrication, machining and joining. The fabrication methodology of a composite part
depends mainly on three factors: (i) the characteristics of constituent matrices and
reinforcements, (ii) the shapes, sizes and engineering details of products and (iii) end
uses. The composite products are too many and cover a very wide domain of applications
ranging from an engine valve, or a printed circuit board laminate, or a large-size boat hull
or to an aircraft wing. The fabrication technique varies from one product to the other. The
matrix types (i.e., whether they are plastics, metals or ceramics) play a dominant role in
the selection of a fabrication process. Similar process cannot be adapted to fabricate an
engine blade made with fibre reinforced plastics and metal matrix composites. The
process parameters may also have to be modified, even when one uses the same matrix
type, but two different matrices. For example, the processing with phenolics requires
additional heating, whereas epoxies can be processed under ambient conditions.
Particulate reinforcements and short fibres are mixed with resin to produce either bulk
moulding composite compounds (BMCs) or sheet moulding composite compounds
(SMCs) which are then used as base materials to fabricate composite parts. One method
commonly used with BMCs is the injection moulding in which the BMC is heated and
then injected into the mould cavity. On the other hand, the comparable moulding method
used for woven fibre fabrics is the resin injection moulding. The process parameters like
temperature, injcection pressure and curing time vary from one method to the other.
Moreover, a composite car body panel, though highly curved and complex in shape may
be compression moulded, while a spar stiffened helicopter rotor blade may have to be
fabricated using filament winding and other moulding methods. Further, the accuracy and
sophistication required to fabricate an aircraft composite wing section may not be
necessary while fabricating a composite bridge deck or a silo. The main purpose of this
chapter is to outline briefly the basic features of common composite fabrication methods.
No attempt is made to elaborate the actual fabrication procedure of a particular composite
component, as this is beyond the scope of the present book.
60
Fibre reinforced plastics or wooden moulds are also used in some cold moulding
processes. The mating surfaces of the moulds are first polished, cleaned and coated with a
release agent. Next a gel coat is applied. The gel coat is a special resin that sticks to the
surface of the moulded part during curing and provides it with an excellent surface finish.
Pigments and other additives are also added to the gel coat resin for colouring as well as
improving its resistance to wear, corrosion, heat, flame, weathering, etc. The gel coat is
not provided, when the moulded part is to be adhesively bonded to another part, as the
coat may not allow proper bonding. Both thermosetting and thermoplastic resins are used
in the moulding materials. Thermoplastics in general and some thermosets in particular
need process temperature higher than the ambient temperature. This is met by heating
either the mould or the moulding. Venting ports are provided in the moulds for escape of
excess resin and volatile matters.
Compression moulding is the most commonly used matched-die moulding
method. It is employed in fabrication of automobile body panels, housings for electrical
appliances and machines, covers, sinks and several other parts. Typical moulds are shown
in Fig. 3.1. The moulds can have a single cavity or multiple cavities with complex curved
shapes. Provision may exist to heat either or both the moulds. The pressure is applied by
mounting the moulds in a mechanical or hydraulic press or by some external means. The
precise application of pressure and temperature and their duration and cycles can be
controlled. The process can also be easily automated. On application of pressure and
temperature, the mould material softens and then flows and fills the mould cavity.
Further, continuation of heat and pressure accelerates curing. The dimensions close to
those of the desired finished part can be obtained in compression moulding. This reduces,
to a great extent, subsequent trimming and machining. The moulding material may be a
predetermined quantity of BMC, SMC, resin coated preforms/fabrics or prepregs. It is
laid on the mould and then the moulds are closed. A barrier along the edge prevents the
resin to flow out. The depth of the barrier also controls the thickness of the part. Heat and
pressure are applied during curing. Once the curing is complete, the mould is opened and
the part is removed.
Some resins like polyesters and epoxies are highly exothermic and may not
require external input of heat during curing. The moulding material with these resins can
be cold pressed. Cold press moulding is relatively less expensive and is suitable, when a
part is smaller in size and simpler in shape (flat or slightly curved panels).
Cold stamping is also similar to compression moulding, but is normally used with
thermoplastic sheets. The thermoplastic sheets are preheated, laid on the mould along
with reinforcements and then cold pressed. An extension of this method to continuous
62
63
penetration and even distribution of resin. For larger mouldings such as boat hulls, resin
is injected at several locations. Also, cold cure resins of low viscosity and long gel time
are preferred, as the injection time is longer in such applications.
In the reaction injection moulding, measured quantities of two liquid precursors
such as a polyol and an isocyanate are mixed in a chamber and then injected into the hot
mould cavity containing pre-laid reinforcements. Chopped strands and particulate
reinforcements can also be blended with precursors prior to injection. The process is
normally used for polymethane based systems and requires a relatively low injection
pressure. It is highly suitable for mass production of composite parts.
are preferred. An improved open mould set-up with pre-curing lay-up details that are
generally employed in a vacuum bag moulding, is shown in Fig. 3.6. The whole
moulding system is covered with a flexible vacuum bagging film made of nylon or
neoprene rubber. The edge of the bag is sealed using vacuum sealing compounds. Layers
of vent cloth, perforated Teflon film, fiberglass bleeders, Teflon coated fiberglass fabrics
and nylon peel ply, in that order, are kept between the vacuum bag and the composite layup. When vacuum is applied, these materials allow attainment of uniform vacuum
throughout and provides path for escape of volatiles, trapped air and excess resin from
the composite lay-up. The vacuum also induces uniform atmospheric pressure on the top
surface of the mould assembly and thereby helps in uniform distribution of resin and
futher consolidation of the laminate. It also provides better finished surfaces. The whole
assembly can be put in an oven or an external heating arrangement can be made, if a high
temperature curing is needed.
In the case of pressure moulding, the vacuum bag is replaced by a pressure bag
and the whole system is covered by a pressure plate (Fig. 3.7). The required pressure is
then applied through an inlet pipe located at the cover plate. In this method, it is possible
to apply pressure higher than one atmosphere. The higher pressure ensures proper
consolidation and densification of the composite lay-up. However, the method cannot be
applied to a male mould.
Autoclave moulding is a highly sophisticated process in which controlled
temperature and pressure can be applied. In addition, vacuum is also applied to suck
volatile matters and entrapped air or gases. The whole assembly as shown in Fig. 3.6 is
put inside an autoclave (Fig. 3.8) which is a pressurized cylindrical hot chamber. Curing
takes place in presence of simultaneous pressure and temperature. After curing, the
mould is taken out of the autoclave and the cured composite is laid with prepregs, as it
permits controlled variation of prescribed temperature and pressure with respect to time.
It yields highly densified and voidless quality products and is therefore greatly favoured
in fabrication of all major aerospace components like aircraft wing parts, control surfaces,
helicopter blades, filament wound rocket cases, pressure bottles, etc.
65
through rollers to squeeze out excess resin and finally wound, under constant tension,
around a collapsible mandrel. The outer diameter of the mandrel corresponds to the inner
diameter of the part to be fabricated. The mandrel is usually made of steel. However,
other materials like plastic foam and rubber are also used in fabrication of some
mandrels. A steel mandrel can be so designed that it can be dismantled mechanically and
removed part by part without damaging the filament wound composite part. Some foam
mandrels can be chemically dissolved. An inflated rubber mandrel can be collapsed by
deflating it. The mandrel is positioned, either horizontally (for helical winding) or
vertically (for polar winding), on a carriage that moved back and forth along the direction
parallel to the rotational axis. In addition to the translational (axial) motion induced by
the carriage, the mandrel can also rotate about its own axis. Both rotational and axial
motions of the mandrel can be properly controlled either manually or using an automatic
system. The rotation of the mandrel about its axis of revolution facilitates winding of
filaments on the outer surface of the mandrel.
There are basically two types of filament winding patterns: helical winding and
biaxial winding. In the helical winding (Fig. 3.9) a constant angle (known as helical
angle) is maintained by controlling the rotational and axial motions of the mandrel. By
reversing both axial and rotational motions, the filaments are wound with a minus helical
angle, -. Structural components having circular cylindrical shapes like tubes, pipes and
cylinders are normally fabricated with alternating helical angle + and . When the
filaments are wound at an angle = 900, the winding is called hoop winding. Similarly,
when =0, it is termed as axial winding. In the biaxial winding pattern, there may exist a
combination of either hoop winding and axial winding pattern commonly employed for
filament winding of circular cylindrical closed end vessels (with or without small end
openings), such as motor cases and pressure tanks, is known as polar winding or polar
wrap (Fig.3.10). A combination of both polar and hoop winding is normally provided for
proper strengthening in the circumferential direction. After winding is complete, the
mandrel is removed from the carriage and placed in an oven, if required, for curing.
Filament wound products for aerospace applications are normally cured in an autoclave.
For such curing, vacuum bagging as described earlier, of the mandrel assembly has to be
carried out before placing it in an autoclave. After curing, the mandrel is dismantled and
the finished part is removed. Filament winding yields a component with a high degree of
fibre volume fraction. Prepreg tapes can also be wound in similar ways.
Filament winding can also be used, when the shape of the part is not a shell of
revolution. The winding is first carried out on an inflated mandrel made of rubber. The
mandrel is deflated, once winding is complete. The deflated filament wound component
66
is placed in a closed match-die mould and the mandrel is inflated again to apply pressure
from inside. The mould is simultaneously heated to facilitate curing. The cured finished
part has the outer shape same as the inner shape of the mould. Several non-circular
sections (e.g., box section and airfoil sections) can be fabricated using this technique.
Braiding is another form of filament winding process and is employed in
fabrication of bars, tubes, bends, etc. with both circular and non-circular hollow sections.
It is carried out on an axially moving mandrel which is positioned through the central
hole of a rotating ring. A number of spools containing continuous rovings are mounted on
the ring. The fibres are pulled out from these spools and wound around the moving
mandrel creating an inter-woven winding pattern which provides high interlaminar
properties.
3.2.4 Pultrusion
Pultusion, to some extent, is analogous to the metal extrusion process. In the
pultrusion process continuous fibre reinforced structural sections can be produced by
pulling the resin-coated filaments through a die unlike in the metal extrusion process,
where hot metallic rods, bars and flats are pushed through a die to produce extruded
parts. The pultrusion process is schematically shown in Fig. 3.11. Continuous fibre
strands taken from a number of spools are sequentially pulled through a resin bath, a
shaping guide and a hot die (or a cold die and an oven). The fibres are coated in the resin
bath and the excess resin is squeezed out. The shaping guide provides a gradual change
from a simpler to a more complex pre-formed shape close to that of the pultruded part.
For example, to obtain a pultruded channel section, a flat form with no flanges is
gradually changed to a channel section of desired dimensions. The final shape is realized
when the preformed shape is pulled through a hot die and gets cured. Continuous strand
mats and woven fabrics can also be pulled along with filament strands to provide better
transverse properties to the pultruded sections. The die is a very critical component in the
fabrication process. It is usually made of chromium plated steel and should have a highly
smooth surface. A smooth surface inhibits sticking of the resin at the entry segment,
where only the gelation of resin, but not curing has been initiated. Thermosets like
epoxies and polyesters are normally used in the pultrusion process. Phenolics can also be
used, but have to be preheated. Experimentation with thermoplastics has also been carried
out. Pultrusion is a continuous process and therefore provides scope for automation. A
pultursion machine SPACETRUDER, designed and developed at Vikram Sarabhai
Space Centre, Trivandrum, India is shown in Fig. 3.12. It can produce continuous lengths
67
of FRP sections such as rounds, square bars, channels, angles, etc. using glass, carbon or
aramid fibres and epoxy or polyester resins.
68
a mandrel. When the solvent is evaporated, the fibre-resin combination forms a rolled
fibre mat on the mandrel surface. The binder resin in precursor wires and fibre mats
decomposes at a high temperature without leaving any residue. Under temperature and
pressure metal sheets or foils melt and diffuse through fibre layers to form a laminate. A
multilayered laminate may have any desired stacking sequence. A monotape (i.e., a
unidirectional lamina) in which a precursor layer or a fibre mat is sandwiched between
two metal sheets or foils, forms the basic building block. Several complex composite
components can be fabricated by stacking monotapes as per design requirements. The
temperature, pressure and their duration are very critical for making good quality
composites. Carbon fibres have been successfully combined with matrices like
aluminium, magnesium, copper, tin, lead and silver to make a wide range of carbon fibre
reinforced metal composites. A number of products ranging from flat plates to curved
engine blades have been fabricated using the diffusion bonding technique. One
interesting example is the 3.6m long high gain antenna boom that acted as a wave guide
for the Hubble space telescope. The boom is made with diffusion bonded carbon fibre
reinforced aluminium (AA 6061) composite and is of tubular cross-section with internal
dimensional tolerances of 0.15 mm. Several other composites, for example, boron,
beryllium and steel fibres in aluminium alloy matrix have been manufactured using the
diffusion bonding process. Large composite sheets can be produced by employing the
vacuum hot rolling technique.
3.3.2 Powder Metallurgy Process
Almost all metals and their alloys can be converted into powder form. Metal
powders are commonly produced by atomization techniques. A stream of molten metal is
disrupted either by impacting another fluid (gas or water) jet under high pressure or by
applying mechanical forces and electrical fields leading to formation of fine liquid metal
droplets which then solidify resulting in fine powder particles. The inert gases, argon and
nitrogen, are used in the gas atomization, and the resulting powder particles are smooth
and spherical with 50-100m diameter. The impact of very high intensity gas pulse
waves in supersonic and ultrasonic gas atomization can lower particle sizes to 10m. The
water jet impact produces irregular particles (75-200 m diameter). Both gas and water
contaminate particles with oxygen. In another method, known as vacuum atomization, the
liquid metal supersaturated with gas under pressure is suddenly allowed to expand in
vacuum causing the liquid to atomise and produce spherical powders with diameters
ranging between 40-150m. In the rotating electrode technique, a prealloyed electrode is
rotated at a high speed (about 250 rps) while it is melted by an arc or plasma beam.
Spherical droplets of the molten material are ejected centrifugally and, on being cooled in
an inert environment, produce high quality, spherical powders with 150-200m diameter.
69
The centrifugal atomization process combined with rapid solidification yields spherical
powders less than 100m diameter. Both the electrohydrodynamic atomization in which
an electrical field is applied on the surface of a liquid metal to emit droplets and the spark
erosion technique, where repetitive spark discharge between two electrodes immersed in
a dielectric fluid produces metal vapour, thereby yielding very fine powders with
diameter as low as 0.5 m or less.
Powder metallurgy is a versatile process but its application to fabrication of metal
matrix composites may not be straight-forward, especially because of the presence of
reinforcement phase.
There are quite a few composite fabrication techniques using continuous fibres of
which two processes that use hot pressure bonding need special mention. In one process
(known as powder cloth process), metal powder filled clothes are first produced by
mixing metal matrix powders with an organic binder and then blending with a high purity
Stoddard solution. On application of low heat, the Stoddard solution evaporates leaving
behind a dough-like mixture which, on rolling, yields a metal powder cloth. Alternate
layers of powder clothes and fibre mats, when hot press bonded, form a composite
laminate (Fig.3.14). The binders usually burn out without leaving any residue. When the
reinforcements are in the form of short fibres and particulates, metal matrix powder and
reinforcements are thoroughly blended, and the blend is degassed to remove volatiles and
then a composite ingot is formed by either hot pressing in vacuum or hot isostatic
pressing. The composite ingot is subsequently used to fabricate structural components
using secondary fabrication processes. Major problems are encountered in controlling the
shape, size and distribution of reinforcements in the matrix. The alignment of short fibres,
elongation of particulates i.e., a sphere changing to an oblate or nonspherical shape, and
uniform dispersion or clustering are the common occurrences that influence the
microstructure of the composite. Figure 3.15 shows an optical micrograph of SiC
particulate (30% by volume)/AA2124 composite a) in the vacuum hot pressed condition
showing the necklace structure of particulate reinforcement around the matrix particles
and b) in the as extruded condition showing the elimination of necklace structure and
improved distribution.
In the thermal spray processes, metal powders, are deposited on the fibre
substrates using either plasma spray or arc spray techniques and composites are
subsequently produced by consolidating these metal matrix coated fibres under heat and
pressure. The plasma spray technique is employed to deposit spherical metal powders
that are injected in the plasma stream (the temperature is about 10,000K and the traveling
speed is around Mach 3) within the throat of the gun. The powder particle size is very
70
critical, because the powder should melt, but not vapourise before it reaches the substrate.
The arc spray technique uses continuous metal matrix wires of 0.16-0.32 cm diameter
instead of metal powders. Two wires of opposite charge are fed through an arc spray gun.
The electric arc produced between the wire tips causes the tips to melt. An argon gas
stream that passes through the gun and between the wires, carries with it droplets of
molten metal and deposit them on the fibre substrates. Both plasma spray and arc spray
techniques have been used to produce composite monotapes by winding continuous
fibres on a mandrel and then spraying metal matrix powders on them. These monotapes
are subsequently used to fabricate structural components using the diffusion bonding
process.
The powder metallurgy process has been used to produce composites such as
boron, carbon and borsic fibres with aluminium alloy, SiC fibres with cromium alloys,
boron and Al2O3 fibres with titanium alloy, tungsten and molybdenum fibres with nickel
alloy and several other composite systems.
3.3.3 Casting
Casting or liquid infiltration is the process in which molten matrix is infilatrated
into a stack of continuous fibre reinforcements or discontinuous reinforcements (short
fibres and particulates) and is then allowed to solidify between the inter-reinforcement
spaces. In the case of discontinuous reinforcements, they can also be pre-mixed with
molten matrices prior to casting, using techniques such as mechanical agitation, mixing
by injection with an injection gun, centrifugal dispersion and dispersion of pellets
(formed by compressing the metal matrix and reinforcements) in a mildly agitated melt.
This pre-mix or the composite slurry is used for subsequent casting. There are several
casting methods that can be used to produce metal matrix composite components. Some
important casting methods are sand and die castings, pressure die castings, centrifugal
casting, squeeze casting and investment casting.
In the sand and die casting process, the preferential concentration of
discontinuous reinforcements, either at the top or at the bottom depending on their
densities lower or higher than the metal matrices, takes place in view of the slow cooling
rate of sand moulds. A more uniform dispersion or dispersoids can be achieved by
agitating the mix, cooling the mould or employing a metal mould. The pressure die
casting produces relatively void free composites and permits fabrication of large-size
parts with intricate shapes. In the centrifugal casting, solidification takes place in a
rotating mould. In this process, the centrifugal acceleration forces the heavier
discontinuous reinforcements to concentrate near the outer periphery and the lighter ones
lie closer to the axis of rotation. Squeeze casting (also known as liquid forging) is the
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process in which the molten matrix is infiltrated, under high pressure, onto a preheated
stack of discontinuous reinforcements or fibre performs laid on a metal die. Solidification
takes place also under pressure. Several critical components have been developed using
squeeze casting. The Toyota piston, made of ceramic fibre and aluminium matrix, is one
such example. In the investment casting, continuous fibre reinforcements are laid using
usual filament winding or prepreg laying procedures. Composites are then produced by
infiltrating the lay-up with a molten matrix under pressure or vacuum.
Casting is the most commonly used process for manufacture of metal matrix
composites. Figure 3.16 exhibits a graphite/aluminium composite ingot and its composite
products.
73
composite parts with irregular shapes. The deposition reaction may be of reduction,
thermal decomposition or displacement type. A typical reaction such as
CH3 Si Cl3 SiC + 3 HCL
is responsible for deposition of SiC vapour. The reagents and vapour deposition
temperatures for a few ceramic matrices are listed in Table 3.1. Plasma has also been
used to assist chemical vapour deposition, for example, as in the case of SiO2 matrix.
The deposition process is carried out under any of these conditions: (i)
maintaining a uniform temperature through out the preform i.e., isothermal condition, (ii)
providing a thermal gradient through the thickness of the preform, (iii) isothermal, but
forcing the flow of reactant gases into the preform, (iv) both with thermal gradient and
forced flow and (v) with pulsed flow, i.e., cyclic evacuation and filling of the reactor
chamber with reactants.
Carbon-carbon composites are fabricated by either resin impregnation and
subsequent carbonization or chemical deposition of carbon vapour. The latter process has
Table 3.1: Typical ceramic matrices, reagents and vapour deposition temperatures
Ceramic Matrix
ZrB2
HfB2
TiC
SiC
B4C
Si3N4
BN
Al2O3
Cr2O3
SiO2
Y2O3
ZrO2
TiSi2
C
Reagents
ZrCl4, BCl3, H2
HfCl4, BCl3, H2
TiCl4, CH4, H2
CH3 SiCl3, H2
BCl3, CH4, H2
SiCl4, NH3, H2
BCl3, NH3, H2
AlCl3, CO2, H2
Cr (CO)6, O2
SiH4, CO2, H2
YCl3, CO2, H2
ZrCl4, CO2, H2
TiCl4, SiCl4, H2
CH4
* plasma assisted
74
Deposition temperature,
o
C
1000-1500
1000-1600
900-1600
1000-1600
1200-1400
1000-1550
1000-1300
500-1100
400-600
200-600 *
1200
800-1200
1400
900-2250
been found to yield superior carbon-carbon composites and has been used to produce
aerospace components such as aircraft brake discs and engine exit nozzles, nose cones,
rotors, combusters, etc. A hydrocarbon reagent, e.g., CH4 may be used along with
hydrogen, nitrogen or any inert gas for chemical deposition of carbon vapour on a carbon
fibre substrate (perform).
3.5 MACHINING
Machining is an important stage of the overall manufacturing process. It helps to
realize finished products with specified dimensions, surface finish and tolerances.
Conventional machining processes require direct contact between the cutting tool and the
part to be machined. The quality of the machined part and the tool wear are two major
concerns in these machining processes. The performance and integrity of the machined
part depend primarily on the quality of machining. The removal of material in a metallic
alloy is based on a shear process. The material removal in a composite may be totally
different from that in metals and their alloys. The application of conventional metal
cutting tools in composites leads to flaws such as fibre damage, delamination and
cracking which are not encountered in metal cutting. The presence of these defects and
tool wear has been observed while applying the machining processes such as shearing,
abrasive cutting, grinding, profiling, punching and drilling on fibre reinforced
composites. Even the use of high speed drilling has not been found to be very much
effective in reducing the fibre damage or tool wear. Tool wear has always been a major
problem in machining composite parts. It depends on the feed rate, cutting speed, cutting
direction, temperature, and relative hardness properties of the tool material and the
composite part to be machined as well as several other parameters. The highest tool wear
is observed for a particular combination of feed rate and cutting speed. The tool wear rate
is found to be inversely proportional to the hardness of the tool, when the tool is harder
than the composite to be machined. Diamond tools normally exhibit a longer tool life.
Tungsten-carbide tools and silicon-carbide grinding wheels are also useful. It is difficult
to machine boron fibre composites because of extreme hardness of boron fibres. Some
special problems arise during machining of aramid fibres. These can be tackled using
specially designed tools which are commercially available.
There are several non-conventional machining methods which avoid direct
contact between the machine and the work piece, thereby eliminating the problem of tool
wear and improving the quality of the machined component. A narrow laser beam of 0.1
mm diameter or less with a power in excess of 108 W/cm2 can be directed to cut various
composite materials. The CO2 laser system with 10.6 m wavelength has been
75
3.6 JOINING
A joint is an essential element in a structural system. However, it is the weakest
link, and therefore the selection of a particular type of joint, its fabrication and/or
assembly need careful consideration. There are two basic types of joints, bonded and
mechanically fastened, which are also applicable to all composite systems. Bonded joints
are preferred, because of their efficient load transfer which is primarily through shear in
the bond layer. The bond shear stress as well as direct or induced peel stresses can be
controlled by configuring and designing the joint properly. Some of the common bonded
joint configurations are illustrated in Fig. 3.17. The mechanically fastened joints (bolted,
riveted, etc.), on the other hand, are relatively inefficient because of high stress
concentrations around bolt holes. The process of load transfer in a mechanically fastened
joint, especially involving deformable bolts or pins and composites, is very complex. The
modes of failure in a typical single-pin bolt joint are shown in Fig.3.18. The residual
strength of such a joint is quite low and is usually less than a half of the composite
laminate strength. However, mechanical fastening is a practical necessity in view of ease
of repeated dismantling and assembly as well as repairability.
Bonded joints are again of two types adhesive bonded and fusion bonded or
welded. An adhesive bonded joint normally involves application of an adhesive layer on
the overlapping surfaces of the adherends. The adhesive layer is usually a thermosetting
76
resin. The bonded joints are, therefore, highly effective for composites with thermosetting
resins. They are also good for metal and even ceramic joints, provided they are not
exposed to temperatures higher than the tolerable limit of the adhesive. The surface
treatment of adherends, prior to the application of the adhesice layer, is necessary to
achieve better adhesion properties. But the thermosetting adhesive layer is not compatible
with thermoplastic composites. Thermoplastic composite adherends need to be fusion
bonded. In fusion bonding no new material is added. The process involves surface
preparation, heating and melting of the bond surfaces, pressing for intermolecular
diffusion and entanglement of the polymer chains and cooling for solidification. The
bond surfaces are treated mechanically and/or chemically to remove all contaminations
including loose particles, dirt, release agent, oil, etc. The heating and melting are carried
out using any of the welding techniques employed in plastics. In the hot-plate welding
process, the surfaces to be bonded are heated by making contact with a hot plate. The hot
gas welding normally employs a hot gas. In the case of a butt joint, similar to that of a
metal joint, a thermoplastic welding rod is also used to fill the joining gaps. The
resistance implant welding rod is also used to fill the joining gaps. The resistance implant
welding is an internal heating method and requires an electrical resistive element to be
embedded on the bond surface. Heating is done by passing an electric current through the
resistive element. There are several other ways of external and internal heating, namely
induction welding, laser and infrared heating, dielectric and microwave heating, friction
heating, vibration welding and ultrasonic welding.
For joining metal matrix composite parts, in addition to adhesively bonded and
mechanically fastened joints, several other joining methods that are used in joining
metals and their alloys can be employed. These are brazing, soldering, diffusion welding,
fusion welding, resistance welding, ultrasonic welding, laser welding and electronic beam
welding. These techniques have been employed in several metal matrix composite
systems, e.g., B/Al, C/Al, Borsic/Al, B/Ti, SiC/Ti, W/Ti, C/Mg, Al2O3/Mg and several
others. The joint efficiencies are found to vary between 25-60%. However, higher
efficiencies have also been noted in some cases, and a joint efficiency as high as 98% has
been realized in the fusion welding of Al2O3 fibres. The fusion bonding or welding of
ceramic matrix composite parts with ceramic marix and metal matrix composite parts,
has not yet been properly investigated.
77
3.7 BIBLIOGRAPHY
1. G. Lubin (Ed.), Handbook of Composites, Van Nostrand Reinhold Co., NY, 1982.
2. Mel M. Schwrtz (Ed.), Fabrications of Composite Materials, American Society
for Metals, Metals park, Ohio, 1985.
3. Mel M. Schwarts (Ed.), Composite Materials Handbook, McGraw Hill Book Co.,
NY, 1984.
4. S.M. Lee (Ed.), International Encyclopedia of Composites, Vols. 1-6, VCH
Publications, New York, 1990-1991.
5. J.W. Weeton, D.M. Fosters and K.L. Thomas (Eds.), Engineers Guide to
Composite Materialals, American Society of Metals, Metals Park, Ohio, 1987.
6. N.P. Cheremisinof (Ed.), Handbook of ceramics and Composites, Vol. 1, Marcel
Dekker, Inc., NY, 1990.
3.8 EXERCISES
1. Describe briefly various moulding processes of composites.
2. Describe an appropriate method of fabrication of an open-ended rectangular
thin-walled box section with the wall consisting of 00/900/450/900/00
laminations.
3. Write notes on (i) filament winding and (ii) pultrusion.
4. Describe the fabrication processes for metal matrix composites.
5. Describe the fabrication processes for ceramic matrix composites.
6. Discuss the joining techniques for MMCs and CMCs.
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
CHAPTER 4
COMPOSITE PROPERTIES MICROMECHANICS
4.1 INTRODUCTION
The mechanical and hygrothermal properties of composites are of paramount
importance in the design and analysis of composite structures. The mechanical properties
constitute primarily the moduli and strength properties. The hygrothermal properties are
coefficient of expansion due to moisture (), misture diffusion coefficient (d), coefficient
of thermal expansion (), thermal conductivity (k) and heat capacity (c).
Micromechanical analyses concern with the theoretical prediction of these properties of
constituent fibres and matrices as well as several other parameters like the shape, size and
distribution of fibres, fibre misalignment, fibre-matrix interface properties, void content,
fibre fracture, matrix cracking and so on. The studies in micromechanics utilize micromodels, as the fibre diameters usually vary in the microscopic scale between 5-140 m.
The micro-models should simulate the microstructure of a realistic composite, but that
usually makes the models highly complex. The problems involving such complex models
are normally tackled utilizing advanced analytical methods as well as numerical analysis
techniques(finite element and finite difference methods). Even in the case of a complex
model, a simplified idealization with a reasonably good approximation of the real
composite is desirable otherwise it may lead to nowhere. It is not intended in this chapter
to present the complete theoretical basis of various micro-models used for the analytical
prediction of all composite properties. The presentation is limited to only a few simpler
cases so as to acquaint the reader of the background of the development in this area.
Additional micromechanics relations for unidirectional composites, that may find use in
design applications, are listed in Table 4.1. Typical properties of some of the common
fibres and matrices are listed in Tables 4.2 and 4.3, respectively. The composite
properties of a few composite systems derived using some of the relations presented in
this chapter are listed in Table 4.4. Tables 4.1 through 4.4 are included at the end of this
chapter.
the stress-strain behaviour. Here E is a material constant and is usually referred as elastic
constant (engineering constant) or Young's modulus. Besides E, the other conventional
engineering constant for a two-dimensional or three-dimensional isotropic body is
Poisson's ratio . The shear modulus G is not independent, but is related to E and as
G = E/2(1+ ). A composite material is essentially heterogeneous in nature, therefore the
engineering constants, defined above, for an isotropic material are not valid. We consider
here a three-dimensional block of a unidirectional composite (Fig. 4.1), in which fibres
are aligned along the x'1 axis. The elastic behaviour for such a three-dimensional body
, E33
(three Young's moduli
is orthotropic, and the engineering constants are E11 , E22
along three principal material axes x'1, x'2, x'3), '12, '13, '23, '21, '31, '32, (six Poisson's
ratios) and G'12, G'13, G'23, (three shear moduli). Of these, the first nine engineering
constants i.e., three Young`s moduli and six Poisson ratios are not independent. Due to
symmetry of compliances (see Eq. 6.18) these are related as given by
12
11
13 13
;
22 11
23
31
;
33 22
32
(4.1)
33
Note that,
(4.2)
Here '12 and '13 are usually referred as major Poisson ratios.
The 'mechanics of materials approach' provides convenient means to determine
the composite elastic properties. It is assumed that the composite is void free, the fibrematrix bond is perfect, the fibres are of uniform size and shape and are spaced regularly,
and the material behaviour is linear and elastic.
Consider a two-dimensional unidirectional lamina (Fig. 4.2), in which we define a
small volume element which represents not only the micro-level structural details but also
the overall behaviour of the composite. A simple representative volume element consists
of an isotropic fibre embedded in an isotropic matrix (Fig. 4.2b). This volume element is
further simplified as shown in Fig.4.2c, in which the fibre is assumed to have a
rectangular cross-section with the same thickness as the matrix. The width ratio is chosen
to be the same as the fibre volume fraction of the composite itself. The objective is to
derive the composite properties (E'11, E'22, '12, G12) in terms of the moduli, Poisson`s
ratios and volume fractions of the fibre and the matrix.
97
and
'11m Wm
(4.3)
(4.4)
(4.5)
Noting that the volume fractions of the fibre and the matrix are
Vf = Wf /W and Vm = Wm / W respectively, Eq. 4.5 reduces to
E'11 = E'11f Vf + E'11m Vm
(4.6)
Equation 4.6 defines the composite property as the 'weighted' sum of constituent
properties and is often termed as the 'rule of mixture'.
also
'22
and
So,
or,
or,
or,
22
22
(4.7)
= W/W
22
22
Vf +
22
22 m
Vm
Vf
V
1
+ m
=
22 22 f 22 m
22 f 22 m
(4.8)
22 f Vm + 22 mV f
98
The micro-model is stressed as in the case of determination of E`11 (Fig. 4.3). The
transverse contraction is noted as W and is contributed by both the fibre and matrix.
Thus,
W = (W)f + (W)m
or,
Now , 12 =
and
'22
(4.9)
22
11
(4.10)
= - W/W
(4.11)
W 11
12 =
or,
(4.12)
The micro-model is now subjected to a shear stress '12 as shown in Fig. 4.5, and
both and the fibre and the matrix are assumed to experience the same shear stress.
'12f = '12 / G '12f and '12m = '12 / G '12m
(4.13)
also,
=
12
(4.14)
12
(4.15)
G12
Substituting Eqs. 4.13 and 4.15 into Eq. 4.14 and eliminating '12 from both
sides, we get
Vf
V
1
=
+ m
G12
G12 f G12 m
or,
G12 =
G12 f G12 m
(4.16)
G12 f Vm + G12 mV f
99
G12 f = G f =
(4.17)
2(1 + f )
G12 m = Gm =
m
2(1 + m )
(4.18)
Equations 4.6 and 4.12 provide a reasonably accurate estimate of longitudinal modulus
E11 and 12, respectively. However, the transverse modulus E22 and the shear modulus
G12, estimated using Eqs. 4.8 and 4.16, are not so accurate mainly due to the reason that
the stresses in both the fibre and the matrix are assumed to be the same. The volume
element considered in the above mechanics of materials approach does not adequately
represent the micro structure of the composite. Advanced analytical methods employ
better micro-models along with the realistic material behaviour and boundry conditions.
The analytical method using a self-consistent field model provides a better estimation of
composite properties in comparison to the mechanics of materials approach. The model
assumes the composite to be a concentric cylinder (Fig. 4.6) in which a transversely
isotropic matrix. Although the assumed micro-model is simple, it permits formulation of
the problem based on the theory of elasticity so that it is possible to achieve the stress and
strain variations in a realistic manner, and the relations for the effective composite
properties are then derived. These properties are expressed as follows:
= 11
f V f + 11
mVm +
11
mVmV f
4( 12 m 12 f ) 2 f m G23
m ) m + ( f m )G23
mV f
( f + G23
12 = 13 = 12 f V f + 12 mVm +
G12 = G13 = G12 m
=
G23
mVmV f
( 12 m 12 f )( m f )G23
m ) m + ( f m )G23
mV f
( f G23
m [ m (G23
m + G23
f ) + 2G23
f G23
m + m (G23
f G23
m )V f ]
G23
m + G23
f ) + 2G23
f G23
m ( m + 2G23
m )(G23
f G23
m )V f ]
[ m (G23
=
m ) m + ( f m )G23
mV f
( f + G23
m ) ( f m )V f
( f + G23
100
(4.19)
(4.20)
(4.21)
(4.22)
(4.23)
22 = 33 = 1 /(
12 2
1
1
+
+
)
11
4 4G23
(4.24)
in which K', G'23, '122 and E'11are defined in Eqs. 4.19 through 4.23.
22 4 12 22
2 11
= 11
23
211
2
(4.25)
with E'11, E'22, K', and '12 defined in the above relations.
Note that for isotropic fibres and matrices,
f = f ;
f = 22 f = 33 f = f ; 12 f = 13 f = 23
11
f = Gf =
G12 f = G13 f = G23
f
2(1 + f )
m = m ;
m = 22 m = 33m = m ; 12 m = 13 m = 23
11
m = Gm =
G12 m = G13 m = G23
and
f = f =
f
3(1 2 f )
m
,
2(1 + m )
; m = m =
m
3(1 2 m )
(4.26)
The strength of a material is defined as the level of stress at which failure occurs.
The strength is a material constant. Most of the isotropic structural materials possess only
one constant i.e., the uniaxial tensile strength. The shear strength is normally related to
the tensile strength. A brittle isotropic material may have different strength values in
tension and compression and may be termed as a two-constant material. In contrast, a
composite is a multi-constant material. Referring to Fig. 4.1, it may be stated that a
unidirectional composite may possess three normal strengths X'11, X'22, X'33 and three
shear strengths X'12 , X'13, X'23. A normal strength may have different values in tension
and compression, as the compressive force usually induces premature failure due to
101
buckling of fibres which have extremely high slenderness ratio. So there are a total of
nine independent strength constants X'11t, X'22t, X'33t, X'11c, X'22c, X'33c, X'12, X'13, X'23.
Attempts made using micromechanical analyses to determine these strength
constants, met with little success. This is primarily due to the reason that the micromodels used in these analyses are grossly unrealistic. In fact, it is extremely difficult to
simulate the realistic composite, as the initial microstructure changes continuously with
the increase of applied stress and propagation of failure in the form of fibre fracture,
matrix cracking, fibre-matrix debond and so on at several points located randomly within
the composite. The brittleness of the fibre and the matrix aggravates the situation. This is
illustrated in Fig. 4.7. Note that lc is the ineffective length. The presence of a single
surface flaw in a brittle fibre causes the fibre to fracture at A (Fig. 4.7a). This induces
high shear stresses and causes the fibre-matrix debond along the fibre direction (Fig.
4.7b). Also when a fibre fractures, a redistribution of stresses in the vicinity results in the
tensile fracture of the adjacent fibre due to stress concentration. This process leads to the
propagation of the crack in the direction transverse to the propagation of the crack in the
direction transverse to the fibres (Fig. 4.7c). In fact, the final failure of a composite is
resulted due to the cumulative damage caused by several micro and macro-level failures.
Longitudinal Tensile Strength, X'11t
X'11
A simple relation can be derived for the longitudinal tensile composite strength
using the 'rule of mixtures' and is expressed as
X'11t = X'11f Vf + X'11m Vm
(4.27)
Here it is assumed that, at a particular level of stress, all fibres fracture at the same time
and the failure occurs in the same plane. That this idealization is grossly unrealistic has
already been argued in the preceding paragraph.
Now, let us examine the validity of Eq. 4.27 for two composite systems: (i) a
carbon/epoxy composite, in which the fibre failure strain is less than the matrix failure
strain, i.e., '11fu < '11mu (Fig. 4.8a) and (ii) carbon/carbon composite when '11fu >
'11mu (Fig.4.8b). In these cases, both fibres and matrices are brittle. In the case of
carbon/epoxy composite, when Vf is much higher than Vm , the strength of the composite
is primarily controlled by the fibre fracture. Once the fibres fail, very little resistance is
offered by the matrix. So, the strength of the composite is given by
X'11t = X'11f V 'f + '11m Vm
(4.28)
102
where '11m is the stress level in the matrix when the fibres fracture. On the other hand,
when Vf is low, there is a sufficient amount of matrix to resist the load after the failure of
fibres. In that case,
X'11t = X'11mt Vm
(4.29)
It is therefore obvious that there exists a limiting value of Vf at which the final failure
changes from the fibre failure mode to the matrix failure mode. One may argue in a
similar way to identify the possible failure mechanisms in the case of a carbon/carbon
composite also (Fig. 4.8b) as well as in the cases of other composites in which either
fibres or matrices or both are ductile. But the fact remains that there is no single relation
which is able to define the uniaxial tensile strength of a realistic composite.
However, Rosen's model of cumulative damage, which is based on the Weibull
distribution of the strength-length relationship, provides somewhat better estimation of
X'11t, when the fibres and the matrix exhibit brittle behaviour. This model assumes that
the composite consists of N fibres of original length L and the weaker fibres fracture due
to the applied tensile stress (Fig. 4.9). The original length is then divided into M
segments, where each segment (bundle or link) is of length 1c. Thus the composite forms
a chain of M bundles (links). When the number of fibres are very large (high Vf) the
strength of each bundle or chain link assumes the same value, i.e., the strength of the
composite becomes equal to the link strength. This is expressed as
X 11 f 1 = (1c ) 1 / exp(1 / )
(4.30)
where and are material constants and can be determined experimentally. The tensile
strength of the composite is then determined using
X 11 = V f X 11 f 1 = V f (1c e) 1 /
t
(4.31)
Note that lc is called the ineffective length or critical fibre length and is determined using
the shear lag stress. It is given by
lc =
X f d
(4.32)
2Xi
where X'f is the tensile fracture strength of the fibre, d is the diameter of the fibre and Xi
is the fibre-matrix interfacial shear strength.
The longitudinal compressive strength X'11c of a unidirectional composite is
primarily affected by the buckling of fibres. In a simplified model, the fibres are treated
as isotropic thin plates lying in the x'1 x'2 plane (Fig. 4.10) and are supported on an
isotrpic elastic medium (matrix). Fibres may buckle in two modes-extension and shear. In
103
the extension mode, the matrix along the length of the fibre experiences alternate
expansion and contraction, whereas the matrix is subjected to shearing deformation in the
shear mode. The compressive strength is then determined employing the strain energy
method. For the extensional mode,
X 11 = 2(V f + Vm m / f )(V f f m / 3Vm )1 / 2
(4.33)
X 11 2V f (V f f m / 3Vm )1 / 2 , f >> m
(4.34)
or,
(4.35)
The transverse strength properties normally depend on the matrix properties. The
transverse tensile strength X'22t may also depend on the fibre-matrix interface strength, as
illustrated in Fig. 4.11. The experimental data for some composites confirm that the
transverse tensile strength enhances with the improvement in the fibre-matrix interface
bond. The actual fracture path, however, is a mixture of fibre-matrix debond, fibre
splitting and matrix cracking. A realistic model should be based on the variation of
statistical data for all these failure modes. Two simple relations, for the prediction of the
transverse tensile strength X'22t and transverse compressive strength X'22c of a
unidirectional composite, are presented as follows:
= [1 ( V f V f )(1 m / 22 f )] X mt
X 22
(4.36)
= [1 ( V f V f )(1 m / 22 f )] X mc
X 22
(4.37)
These relations assume that the transverse strength of a composite primarily depends on
the strength of the matrix.
104
fibres and polymer matrices are moisture permeable. For the diffusion of moisture along
the fibre direction (x'1 axis), the moisture diffusion equation assumes the form
C
2C
= d11
t
x12
(4.38)
where C is the moisture concentration per unit volume, t is time and d'11 is the
longitudinal moisture diffusion coefficient of the composite.
Steady state condition
(4.39)
(4.40)
x1
L
(4.41)
C
dC
= d11 0
dx1
L
(4.42)
The total rate of moisture diffusing through the cross-section of the concentric
cylinder is given by
c = R 2f q11
f + ( R 2 R 2f )q11
m
R 2 q11
(4.43)
Note that
and
f = d11 f
q11
C
dC
= d 11 f 0
dx1
L
m = d11 m
q11
C
dC
= d11 m 0
L
dx1
(4.44)
105
where d'11f and d'11m are the longitudinal moisture diffusivities for the fibre and the
matrix, respectively. Substituting Eqs. 4.42 and 4.44 in Eq. 4.43 and noting that
Rf2/R2 = Vf and (R2 - Rf2) / R2 = Vm one obtains
d'11 = d '11f Vf + d'11m Vm
(4.45)
when the fibres (e.g., glass, carbon, etc.) are impermeable to moisture
d'11 = d '11m Vm
(4.46)
The transverse moisture diffusion coefficient d '22 can also be determined using a
similar self-consistent field model and is, given as
= d 22
m
d 22
f + d 22
m ) + (d 22
f d 22
m )V f ]
[(d 22
(4.47)
f + d 22
m ) (d 22
f d 22
m )V f ]
[(d 22
1Vf
(4.48)
1+Vf
The longitudinal and transverse thermal conductivities k'11 and k'22 of the
unidirectional composite can be determined by replacing 'd ' with 'k' in Eqs.4.45 and 4.47,
respectively. Note that, in that case, heat conduction takes place both through the fibre
and the matrix. The other transport properties can also be derived in a similar way using
Eqs. 4.45 and 4.47.
Expansional Strains
11
11
f=
and also 11
+ 11
11 f
f
11
f ; and also
+ 11
m=
11
106
11 m
m
11
m ;
+ 11
e
(4.49)
11
e )11
11 = (11
and
f 11
f e )11
f ; 11 m = (11
m 11
m e )11
m
11 f = (11
(4.50)
Assuming free expansion '11 = '11e, the first relation of Eqs. 4.50 yields
'11 = 0
(4.51)
Therefore,
'11 W = '11f Wf + '11m Wm = 0
or,
f 11
f e )11
f W f + (11
m 11
m e )11
mWm = 0
(11
(4.52)
f =11
m =11
m =11
e and V f = W f / W and
Dividing Eq. (4.52) by W and noting that 11
Vm = Wm / W one obtains
=
11
e
f e 11
f V f + 11
m e 11
mVm
11
(4.53)
f V f + 11
mVm
11
11 =
f V f + 11 m 11
mVm
11 f 11
(4.54)
f V f + 11
mVm
11
f V f + 11
mVm
11
(4.55)
The transverse thermal expansion coefficient '22 is then derived from Eq, 4.55 in a
similar way
f V f + 11 m 11
mVm
11 f 11
f V f + 11
mVm
11
= 33
= [ 12 f V f + 12 mVm ]
22
107
(4.56)
The transverse moisture expansion coefficient '22 is obtained from Eq. (4.56) by
replacing '' with ''.
P= Vf Pf + Vm Pm ,
where P=K,G
and E = 9 KG / (3K+G)
= (3K-2G) / (6K+2G)
(4.58)
(4.59)
The properties predicted by Voigt model (highest) and Reuss model (lowest) are
two extremes to the real values. Several improved analytical models are known to exist,
but are not easily amenable to simple design uses. The Halpin-Tsai model, which is based
on a semi-empirical approach, is popular and provides both upper and lower bounds that
fall within the Voigt and Reuss limits. Simple relations that are developed based on an
improved combining rule are found to provide a reasonably good estimate of the
properties of an isotropic composite (Pf > Pm and 0 < f < 0.5).
These are presented as follows:
=
m [1 + f {( f m ) /( f + m )}]
1
2
[1 f {1 + (1 f )}{( f m ) /( f + m )}]
2
(4.60)
with P = K,G.
For bulk modulus, : =
2(1 2 m )
1 + m
7 5 m
8 10 m
(4.61)
Young 's modulus E and Poisson 's ratio are then determined from Eqs.4.60 and
4.61 using Eqs.4.58.
The thermal expansion coefficient is given by
m f 1 f
m
f m f m
= V f f + Vm m + f m
109
(4.62)
A simple model assumes a randomly oriented short fibre composite as a quasiisotropic micro-laminate in which each lamina consists of a group of short fibres oriented
along a particular direction. P is determined using the modified Halpin-Tsai relation as
given by
=
m [1 + f {( f m ) /( f + m )}]
[1 f {( f m ) /( f + m )}]
(4.63)
where for
E '11, longitudinal modulus, = 2l / D
E '22, transverse modulus, = 2
G '12, inplane shear modulus, =1
G '23, transverse shear modulus, = (3 4 m)-1
Note, that l and d are the length and the diameter of the short fibre, respectively. Both the
matrix and the fibre are isotropic in nature. The Poisson 's ratio '12 is estimated using the
simple mixture rule.
The longitudinal tensile strength is dependent on the critical fibre length lc (Eq.
4.32) and is given by
l
t = f (1 c )V f + m Vm
11
l
where 'm is the stress on the matrix when the fibre breaks.
110
Vf + Vm + Vv =1
(1)
(2)
(3)
4. Composite density
= f Vf + mVm
(4)
1
1)]
f
(5)
1
1)]
m
(6)
22 = 33 = m /[1 V f (1 m / 22 f )]
(7)
8. Shear moduli
(8a)
= Gm /[1 V f (1 Gm / G23
f )]
G23
(8b)
9. Poisson's ratio
= V f 23
f + Vm (2 m 12 22 / 11
)
23
(9)
c V f 11
f
11
(fibre crushing)
(10a)
111
X 11 c Gm / 1 V f (1 Gm / G12 f )
(microbuckling)
(10b)
X 11 c 10 X 12 + 2.5 X mt
11.
(10c)
m Vf
(11a)
1 V f (1 m / 22 f )
22 = 33 = m (1 2 V f /
2
1 ( mf
Vf /
m
4
1
tan
+
2
mf
1
/
V
+
1
/
V
mf
f
mf f
(11b)
22 = 33 = m +
12.
V f ( f m ) m
0.5Vm ( f m ) + m
; (for MMCs)
(11c)
= d 33
= (1 V f )d m
d 22
(12a)
= d 33
= d m (1 2 V f / )
d 22
d
+ m
d mf
1 (d mf2 V f / )
4
1
tan
2
1
/
+
d
V
1 (d mf V f / )
mf
f
(12b)
11 =
f V f ( f / m ) + mVm
(13a)
( f / m 1)V f + 1
= 33
= 22
f V f + (1 V f )(1 + V f m 11
f / 11
) m
22
(13b)
= 33
= f V f (1 + f ) + mVm (1 + m ) + 11 ( f V f + mVm )
22
(13c)
= 33
= f V f + mVm +
22
V f Vm ( f m m f )( f m )
V f f + Vm m
; (for MMCs)
(13d)
112
14.
22 = 33 = m (1 V f ) 1 +
15.
V f 22 + (1 V f ) m
V f (1 V f ) m
(14)
Heat capacity
C=
( k f f C f + k m m Cm )
(15)
113
S.
N0.
Property
Boron
Carbon
(T300)
Kelvar
-49
SGlass
EGlass
Rayon
(T50)
1.
Fibre diameter, d m
140
12
2.
Density, f gm /cm3
2.63
1.77
1.47
2.49
2.49
1.94
3.
Longitudinal Modulus,
E'11f GPa
400
220
150
85
75
380
Transverse Modulus,
E'22f GPa
400
14
4.2
85
75
6.2
Longitudinal Shear
modulus, G'12f GPa
170
2.9
36
30
7.6
Transverse Shear
modulus, G'23f GPa
170
4.6
1.5
36
30
4.8
Longitudinal Poisson's
ratio, '12f
0.2
0.2
0.35
0.2
0.2
0.2
Transverse Poisson's
ratio, '23f
0.2
0.25
0.35
0.2
0.22
0.25
1.30
0.92
1.05
0.71
0.71
0.84
Longitudinal Heat
conductivity k'11f
W/(mk)
38.0
1003.0
2.94
36.30
13.0
1003.0
Transverse Heat
conductivity k'22f
W/(mk)
38.0
100.3
2.94
36.30
13.0
100.3
Longitudinal thermal
Expansion coefficient,
'11f 10-6 m/m/K
5.0
1.0
-4.0
5.0
5.0
7.7
Transverse thermal
expansion coefficient,
'22f 10-6 m/m/K
5.0
10.1
54
5.0
5.0
10.1
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
114
S.
N0.
Property
Boron
Carbon
(T300)
Kelvar
-49
SGlass
EGlass
Rayon
(T50)
14.
Longitudinal
compressive strength,
X'11ft MPa
4140
2415
2760
4140
2760
1730
Longitudinal
compressive strength,
X'11fc MPa
4830
1800
500
3450
2400
1380
700
550
400
1050
690
350
15.
16.
S
Property
No.
1.
2.
3.
4.
5.
6.
Polyimide
Epoxy
Phenolic
Polyester
Nylon
6061
Al
Nickel
Titanium
Density,m
gm /cm3
1.22
1.3
1.2
1.2
1.14
2.8
8.9
4.4
Young's
Modulus, Em
GPa
3.45
3.45
11
3.45
70
210
110
Shear
Modulus, Gm
GPa
1.28
1.28
4.07
1.11
1.28
26.12
81.40
44
Poisson's
ratio, m
0.35
0.35
0.35
0.35
0.35
0.34
0.29
0.25
Heat
capacity, Cm
kJ/(kgk)
1.05
0.96
1.30
1.15
1.67
0.96
0.46
0.39
Heat
conductivity,
km W/(mk)
2.16
0.18
0.21
0.25
0.19
171
62.0
7.0
115
7.
8.
9.
10.
11.
12.
Thermal
expansion
coefficient,
m10-6 m/m/k
36.0
64.3
80.0
80.0
46.0
23.4
13.3
9.5
Moisture
diffusivity,
dm10-13 m2/s
0.39
1.637
1.20
1.80
1.10
0.0
0.0
0.0
Moisture
expansion
coefficient,
m m/m/C
0.33
0.38
0.38
0.50
0.45
0.0
0.0
0.0
Tensile
strength, Xtm
MPa
120
90
60
60
81.4
310
760
1170
Compressive
strength, Xcm
MPa
210
130
200
140
60.7
310
760
1170
Shear
strength, Xsm
Mpa
90
60
80
50
66.2
180
440
675
116
S. Property
No
Kelvar/
Epoxy
T300/
Epoxy
Boron/
polyimide
Fomulae
used
1.
Density, gm /cm3
1.40
1.58
2.07
Eq.4*
2.
91.38
133.38
241.38
Eq.4.6*
3.
4.00
8.29
14.87
Eq.7*
4.
0.35
0.26
0.26
Eq.4.12*
5.
0.484
0.424
0.394
Eq.9*
6.
2.26
3.81
5.53
Eq.8a*
7.
1.44
2.90
5.53
Eq.8b*
8.
1.836
601.87
23.66
Eq.4.45*
9.
0.57
0.72
6.95
Eq.11b*
1.017
0.933
5.28
Eq.15*
-2.48
1.99
5.28
Eq.4.54*
61.32
2.73
1.48
Eq.13b*
117
4.4 BIBLIOGRAPHY
4.5 EXERCISES
(Use material properties and formulae given in this chapter for numerical
results)
1. Using simple rules of mixture, derive expressions for E'11, E'22 , '12 and G'12.
2. For a matrix of given weight, what should the weight of fibres so that the fibre
volume fraction of the composite is 0.7 i.e., Vf = 0.7.
3. For a boron/ polyimide composite (Vf = 0.7) determine the values of E'22 and G'22
using various formulae and make a comparative analysis.
4. For a carbon/aluminium composite (Vf = 0.5) determine the values of E'11, E'22 ,
'12 and G'12.
118
5. Determine d '11 and d '22 for a carbon/epoxy composites (Vf = 0.7) and for
Kevlar/epoxy composite (Vf = 0.6 and df = 5 dm).
6. Determine k '11 and k '22 for a carbon polyimide and boron/polyimide composites
(Vf = 0.7).
7. Determine '11 and '22 for a boron/aluminium composite (Vf = 0.5).
8. Determine '11 and '22 for a Kevlar/epoxy composite (Vf = 0.7). Assume 'f = 0.5
'm.
119
120
121
122
123
124
125
CHAPTER 5
TEST METHODS
5.1 INTRODUCTION
Testing is a very broad and diverse discipline that concerns with the (i)
characterization of physical, mechanical, hygral, thermal, electrical and environment
resistant properties of a material, that are required as design input, (ii) quantification of
inclusions, voids, cracks, delaminations and damage zones for design assessment, and
(iii) testing and qualification for final product realization. Testing, at the final stage may
also involve application of simulated service loads and exposure to accelerated
environmental conditions. Testing, in fact, is a continuous process, it interacts with a
product at every stage of its design and development and, in most cases, continues until
the product ensures optimum performance requirements even after it is put to a certain
period of continuous service.
The testing of composites is much more involved than that of most other
materials. The number of material parameters to be determined is quite large. Take the
case of a three-dimensional unidirectional composite (Fig. 5.1). The mechanical
parameters that are to be generated are three longitudinal moduli (E'11, E'22 , E'33 ), three
Poisson 's ratios ( '12 , '13, '23 , ), three shear moduli (G'12, G'13, G '23) and nine strength
constants six normal strengths (X'11, X'22, X '33, in tension and compression) and three
shear strengths (X'12, X'13, X'23) and likewise ultimate tensile, compressive and shear
strains. Besides, there are important parameters, namely moisture diffusivities (d '11, d '22,
d '33), coefficients of moisture expansion ('11, '22, '33), maximum moisture content
( ) , thermal conductivities (K'11, K'22, K'33 ), coefficients of thermal expansion '11,
'22, '33 ), heat capacity ( C ) and several other parameters related to impact, fracture,
fatigue, creep, viscoelasticity, plasticity, strain-hardening, etc.
A specimen plays a vital role in realizing the desired test objective. The shape and
size of a specimen and its test requirements vary from one test to the other. The
heterogeneity and anisotropy of composites control the specimen design. A ' dog bone '
type specimen may be used for the tensile testing of a quasi-isotropic composite
(particulate or randomly oriented short fibre composite) whereas a unidirectional
composite requires a flat specimen with end tabs. A specimen to study the microstructure
may need a Scanning Electron Microscope so as to obtain finer details of individual
reinforcements, interfacial bonds, voids, micro-cracks, etc., on the other hand the testing
126
faster and severely limit the integrity of a structure. They also act as pockets in which
diffused moisture or water can accumulate thereby causing further degradation of the
material and structure. The detection and quantification of delaminations, especially the
tight ones, are of major concern to NDT personnel. Besides, there are several defects like
cracks, voids, inclusions, debonding, disbanding, etc. which need to be evaluated using
NDT techniques. The purpose here is not to make a critical assessment of the progress
made in the area but to present a brief account of some important NDT methods that are
the current trend-setters in composite applications. The reader should refer to the recently
published literature for more information on the prospects and limitations of a particular
method. However, one should keep it in mind that an NDT method is better learnt, when
it is used in practice.
(0.9975)a
( a + w b)
(5.1)
where a is the weight of the specimen in air, b is the total weight of specimen and sinker
completely immersed, while the wire is partially immersed and w is the weight of a fully
immersed sinker but partially immersed wire.
The density of a composite can also be determined in a similar way.
5.2.2 Fibre Volume Fraction (ASTM D 3355-74)
The matrix phase in this method is first digested by burning in an oven or using a
digesting liquid. The fibres remain unaffected. They are cleaned and then weighed. The
fibre volume fraction V f is then determined using the relation.
V f = ( w f / f ) /( w / )
(5.2)
where w and are the composite weight and composite density, respectively, and wf and
f are those for the fibre.
128
4
4L
and f = max2
2
d .u
d
(5.3)
where P,d and u are the load, fibre diameter and axial displacement, respectively.
5.2.4 Matrix Tensile Properties (ASTM D638-80)
A 'dog bone' specimen (Fig. 5.3a) is commonly used for a polymer material, and
the strength Xm corresponds to the ultimate failure load. The Young's modulus Em and
ultimate strain mu are measured using electrical resistance strain gauges located at the
centre of the specimen to determine m. For thin polymer sheets (in case it is not possible
to make thick sheets), a flat specimen (Fig. 5.3b) is recommended. The following
relations are used:
m =
1
;
WT 11m
m =
m
11
and m = max
22 m
WT
(5.4)
High modulus and high strength fibrous composites cause special problem of grip
integrity. Wedge action frication grips are used to hold the specimen. The materials for
the tabs should have lower modulus of elasticity and higher percentage of elongation. The
tab thickness may range from 1.5 to 4 times the specimen thickness. Typical specimen
dimensions are presented in Fig. 5.4. The longitudinal tensile properties
, 11
12 ,11
u as well as transverse tensile properties 22 , 22 , 21
,22u for a
11
unidirectional lamina can be determined following this test method. For longitudinal
properties a 00 lamina with the width W= 12.7mm is employed, and for transverse
properties a 900 lamina with W = 25.4mm is used. The specimens are loaded
monotonically at a recommended rate of 0.02 cm/min. The applied loads as well as
longitudinal and transverse strains are measured. The determinable characteristics are
computed using stress-strain plots and simple relations as given below:
129
=
For 00 specimen : 11
1
= 11 max
; 12 = 22 ; 11
WT 11
WT
11
(5.5)
1
= 11 ; 22 = 22 max /WT
; 21
For 900 specimen: 22 =
22
WT 22
5.2.6 Inplane Shear Properties (ASTM D 3518-82)
Several test methods, namely picture frame, rail shear (single and double), tube
torsion, plate twist and tension testing of an off-axis specimen, were developed to
determine the inplane shear properties of a unidirectional lamina. All these methods
require complex test specimens or special test fixtures. The off-axis composite in which
all fibres are oriented at an angle , provides a simple specimen configuration (Fig. 5.5a).
The relation used to determine the inplane shear modulus is given by (see Eq. 6.41)
2
1
1
m4 n4
=
+
+ m2n2 (
12 )
11 11
22
G12
11
(5.6)
However, the testing of an off-axis specimen requires greater care because of coupling of
normal stress and shear stress. The coupling introduces bending moment and shear forces
(Fig. 5.5b) at the ends where it is attached to the grips. This in turn requires complex end
fixtures to loosen the end fixity. The other alternative is to test a long specimen so that
the middle portion of the specimen remains unaffected.
ASTM D 3518-82 specifies a simple test method in which a 450 symmetric
laminate specimen (Fig. 5.6) is subjected to a tensile load. The specimen details
(including end tabs details) are those given in ASTM 3039-76. The width W of the
specimen is 12.7mm. The applied load and both longitudinal and transverse strains are
continuously recorded till failure. The shear stress and shear strain are computed at the
different levels of the applied load from the relations
12 = / 2WT
and 12 = 11 + 22
(5.6a)
12
12
and
=
12
max
2 WT
(5.7)
130
The premature failures, namely, fibre buckling, fibre breaking, matrix shearing,
etc. are commonly encountered in a compression test. The main problem here is to ensure
that the specimen failure is by compression. The specimen gauge length should be
sufficiently short to restrict the failure mode to a truly compressive one. Besides the
specimen ends are likely to get damaged due to want of close contact at all points
between the end faces of the specimen and the platens of the testing machine during
loading. Further, the specimen centerline should be perfectly aligned so as not to induce
any eccentricity with respect to the load path. All these require an appropriate specimen
configuration and a complex loading fixture.
Three standard methods are currently available to determine the true compressive
properties. The details of the testing procedure, specimen configuration, loading fixture,
etc. are presented in ASTM D 3410-87. Of these the most commonly used method
employs a Celanese test fixture (Figs. 5.7 and 5.8). The test fixture consists of truncated
conical collet type friction grips contained in matching cylindrical end fittings (tapered
sleeves). The colinearity of the end fittings is maintained by a hollow cylinder that houses
all fittings. A central opening in the central part of the hollow cylinder provides an access
to the gauge length of the specimen. A spacer is used to separate the grips and allow them
to be closed with a preload, without preloading the specimen. The assembled fixture with
specimen (Fig. 5.9) is loaded between the flat platens of the testing machine. The hollow
cylinder, however, does not carry any load during the test. The recommended loading rate
is 0.017 mm/mm/s.
The applied load P and strains (longitudinal and transverse) are measured at
regular intervals. The compressive strength and longitudinal modulus, and Poisson's ratio
for a longitudinal (00) specimen are computed from
c=
11
max
22 c
1
c
c
; 11 =
. c ; 12 = c
B.T
BT 11
11
(5.8)
The properties for a transverse (900) specimen can also be determined in a similar way.
5.2.8 Interlaminar Shear Properties
The shear moduli G'13 and G'23, and shear strengths X'13 and X'23 (Fig. 5.1) are
normally termed as interlaminar shear properties. There are no reliable methods for
determination of all interlaminar shear properties. ASTM D 2344-84 specifies the
determination of the interlaminar shear strength X'13 only. The apparent shear strength
determined using this method should be used only for quality control and specifications
purposes, but not as design criteria. Both flat and ring short beam specimens (Fig. 5.10)
131
can be used for which the span to thickness ratio is 4 for most composites, except glass
fibre composite when it is 5. For the flat specimens, the corresponding length to thickness
ratios are 6 and 7 so as to provide allowance for the support pins (3.2 mm ). The
loading nose consists of a 6.35 mm dowel pin. The recommended crosshead speed is
1.3 mm/min.
The apparent interlaminar shear strength is obtained using
=
13
0.75max
bh
(5.9)
133
HI. There are other HI methods which are used for specific purposes. The 'simulataneous
method' or real time HI first creates a hologram of the object in a desired reference state,
which is later used as a reference hologram with respect to which subsequent changes in
the object position are recorded by filming the hologram image. The 'time averaging
method' is used to record small amplitude oscillations of vibratory parts. The hologram of
a vibrating body is first recorded on a film for a time interval longer than the period of
oscillation and in the process a set of holograms are superimposed. The resulting
hologram when reconstructed, reveals nodal lines as dark interference stripes.
HI has a great potential for NDT applications. The capability of HI is enhanced
considerably after the introduction of video and popular with the NDT personnel working
in the field of composites and composite structures. The real time monitoring of a
component using HI, especially during the service life, still poses a problem as it is not
easy to isolate vibration in the production and in-service environment. The vibrational
displacement of the object as small as one-quarter wavelength of the laser light may
produce fringes on the hologram. The use of phase-locked holography may alleviate
problems associated the low frequency environmental vibration. The phase-locked
holography uses the diffuse reflection of an unexpanded beam shone on a small portion
of the test object as the reference beam. Another important development in this area is the
electronic shearogrphy in which no separate reference beam is used. In this case, the
returning object beam is doubly imaged with a video system. One image is then found to
be slightly shifted or sheared relative to the original one. This shearing fringe pattern can
be isolated from the real fringes.
5.3.3 Radiography
(5.10)
where I is the intensity of the transmitted beam, I0 is the intensity of the incident beam,
is the absorption coefficient of the medium and h is the thickness through which the beam
travels. The absorption coefficient depends not only on the material, but also on the
wavelength of X-rays.
134
Thus it is observed from Eq 5.10 that the X-ray beam attenuates when it passes
through a material. The attenuation depends on the absorption coefficient and the
thickness of the material. If there exists any defect, say, a void, in the material, the void
( =0) does not absorb X-rays. So the intensities of the X-ray beams passing through the
material thickness with and without a void will be different. When these transmitted
beams are allowed to strike a photographic film, they create a contrast on the exposed
film or radiograph (i.e., more the intensity, darker the film appears) from the knowledge
of which the existence of a void can be predicted. It is also possible to determine the
thickness and composition of a material by examining differences in the exposed film.
Fig. 5.13 illustrates the principle how the radiograph is produced when a stepped
specimen containing a hole is exposed to X-rays.
Normally voids of small sizes (closer to fibre dimensions), and cracks and
delaminations that exist normal to the X-ray beam are not easily detectable. However,
inclusions, cracks, delaminations and other material defects and damages that are aligned
parallel to the X-ray beam can be readily revealed. The X-ray radiography has also been
applied to investigate the microstructural details of damages using low energy X-rays as
well as using an X-ray opaque penetrant (e.g., tetrabomo-ethane or zinc iodide). The
penetrant, however, should not react chemically with the constituents of the composite
medium. The development of radiography with microfocus (in which electrons are
focused on a small area by means of a magnetic field) opens up new vistas for locating
smaller details closer to fibre dimensions (10m). Figure 5.14 shows the microfocal
radiograph of a carbon composite panel with defects such as Teflon pieces, steel mesh,
steel wire and steel balls. Microfocus radiography combined with real time image
processing can be conveniently applied to investigate the nucleation and growth of
cracks, delaminations and damages in composite and honeycomb structures.
A large portion of the attenuation of the X-ray beam, especially with low X-ray
photon energies is due to Compton scattering. The X-ray backscatter imaging uses the
process of recording and investigating scattered radiation from the object. The
backscatter radiation provides quantitative information about variations in density due to
presence of flaws, delaminations, etc. as well as change in materials. The method is found
to be very useful for the inspection of laminated composite pressure vessels and motor
cases, and very tight delaminations can be easily detected.
Computerized tomography (CT) provides a three-dimensional image of the
desired section of an object and therefore all minute details of the variations in the image
slice are recorded. The image is called a tomogram (after the Greek word tomos means 'to
cut'). A point source of X-rays or gamma radiation is collimated to a flat, fan shaped
135
beam which penetrates the slice of an object under inspection. The intensity of the
transmitted beam is recorded by a detector. The movements of the beam and the recorder
can be synchronized when the beam is rotated about the object along with the recorder
and thereby a three-dimensional scanning of the whole slice is carried out. CT is now
widely used in medical diagnostics and offers a great potential for uses in composite
materials and structures.
Neutron radiography is another NDT technique which is finding applications in
polymer composite structures. However, the major limitation of this method is that a
transportable neutron source should be available at the site of inspection.
5.3.4 Thermography
136
5.3.5 Ultrasonics
(5.11)
where
I is the intensity of the transmitted sound wave,
I0 is the original intensity of the sound wave,
is the attenuation constant
and
137
echo C-scan can provide a map of all flaws located at different depths. The method is
also very sensitive to foreign body inclusions. Even the existence of a piece of paper or a
similar material contained within a laminate can be easily identified from the reflected
signal strength.
The transmitted ultrasonic signals can also be monitored by placing a probe
(receiver) on the bottom surface of the specimen. This is called the 'through-transmission'
ultrasonic test. The presence of a flaw will reduce the intensity of transmitted signals. The
through transmission ultrasonic technique is relatively more popular in composite
applications. The method also permits ease of automation. A 'through transmission'
ultrasonic C-scan provides complete information of the quality of an inspected part.
Delaminations, inclusions and other defects normal to the ultrasonic beam are easily
identified in the C-scan mapping. High frequency transducers (5 to 10 MHz) are
employed to locate small defects or cracks parallel to the beam. Short focus transducers
with 15 MHz are also being used in the ultrasonic C-scan system. High frequency
transducers provide the sharper image of a defect and therefore help identification.
There are several other ultrasonic test techniques that are receiving sufficient
attention in recent years. The 'ultrasonic polar backscatter' technique employs slightly
angled beams. This helps detection of matrix cracking in oriented plies. The 'ultrasonic
resonance' method makes use of the fact that the existence of a delamination reduces the
normal surface stiffness of the material. A continuous ultrasonic wave is transmitted
through the material, and the mechanical stiffness or impedance of the material is
monitored. The reduced surface stiffness due to presence of a delamination decreases the
surface loading on the ultrasonic probe and a shift in the phase, amplitude or resonant
frequency is observed. The 'ultrasonic correlation' method enhances the sensitivity of
ultrasonic signals (higher signal to noise ratio) by making use of a continuous wave
cross-correlation technique. The method is very useful for highly attenuative composite
materials. The 'acousto-ultrasonic or stress wave factor' test technique employs an
ultrasonic transducer to send a simulated acoustic emission pulse through the test object.
A defect or damage can modify the waveform which is monitored at a distance away
from the source and is analysed. The 'ultrasonic microscopy' can image microstructural
differences on the surface of a material. The reflection scanning acoustic microscope uses
a very narrow high frequency (100 MHz to 1GHz) ultrasonic beam to scan the object line
by line. Its limit of resolution is that of an optical microscope but the acoustic imaging, in
some cases, provides additional information.
One of the major disadvantages of the ultrasonic NDT method is that a coupling
agent is needed between the probe and the specimen to transmit and receive ultrasound
138
signals. Normally either the specimen is immersed in a water bath or a water jet is
directed to the specimen. Other coupling agents are also used. The coupling agents may
have a deleterious effect on the specimen material. Further, this also poses special
problems, when the size of a part to be inspected becomes large. The other alternative in
such situations is to make use of transducers with dry coupling. The transducer is coupled
acoustically to the specimen via a plastic material which is attached to the tip of the
transducer. Typical CRT patterns from artificially embedded defects (paper and Teflon)
in a carbon-carbon composite material are illustrated in Fig. 5.18.
ASTM D618-91
ASTM D792-75
ASTM D 1505-75
ASTM D 3355-74
ASTM D 3379-75
ASTM D2324-76
ASTM D 4018-81
ASTM D 638-91
ASTM D 695-91
ASTM D 3039-89
ASTM D 3552-77
139
ASTM D 2291-80
ASTM D 2290-92
ASTM D 790-91
ASTM D 3518-82
ASTM D 3918-80
ASTM D 4475-85
ASTM D 3914-84
ASTM D 3916-84
ASTM D 3914-80
ASTM D 3410-87
ASTM D 2344-84
ASTM D 3479-76
ASTM D 671-78
ASTM D 2585-90
ASTM D 2105-90
ASTM D 897-78
ASTM D 3876-79
ASTM D 3846-85
ASTM D 1623-78
ASTM D 1621-79
ASTM D 747-90
ASTM D 696-91
ASTM D 648-88
ASTM D 3917-88
ASTM D 543-87
ASTM E 162-90
ASTM D 2843-88
141
5.4 BIBLIOGRAPHY
1. Annual Book of ASTM standards, American Society for Testing and Materials,
Philadelphia, 1992.
2. R.B. Pipes, R.A. Blake, Jr., J.W. Gillespie, Jr. and L.A. Carlsson, Test Methods,
Delware Composite Design Encyclopedia, Vol.6, Technomic Publication Co.,
Inc., Lancaster, 1990.
3. K.G. Boving (Ed.), NDE Handbook, Butterworth, London, 1989.
4. T.S. Jones and H. Berger, Nondestructive Evaluation Methods for Composites,
International Encyclopedia of Composites (Ed. S. M. Lee),Vol.4m VCH, N.Y.,
1990, p.37.
5. E.G. Henneke, Nondestructive Evaluation of Advanced Composite Materials,
Proc. Indo-US workshop in Composite for Aerospace Application, Bangalore,
India, 1990, p.41.
6. I.G. Scott and C.M. Scala, A Review of Nondestructive Testing of Composite
Materials, Non-destructive Testing International, 15, 1982, p.75.
7. J.H. Williams and S.S. Lee, Acoustic Emission Monitoring of Fibre Composite
Materials and Structures, J Composite Materials, 12, 1978, p.348.
8. J.B. Abbiss, M J Marchant and A C Marchant, Recent Application of Coherent
Optics in Aerospace Research, Optical Engineering, 15, 1976, p.202.
9. D.W. Oplinger, B.S. Parker and F.P. Chiag, Edge-Effect Studies in Fibre
Reinforced Laminates, Experimental Mechanics 14, 1974, p.347.
10. B.G. Martin, Analysis of Radiographic Techniques for Measuring Resin Content
in Graphite Fiber Reinforced Epoxy Resin Composites, Materials Ebaluation, 35,
1977, p. 65.
11. D.J. Hagemaier and R H Faesbender, Nondestructive Testing of Advanced
Composites, Materials Evaluation, 37, 1979, p. 43.
12. R.L. Crane, S. Allinikor and F. Chang, The use of Radiographically Opaue Fibers
to aid the Inspection of Composites, Materials Evaluation, 36, 1978, p. 69.
13. F.H. Chang, D.E. Gordon, B.T. Rodini and R.H. McDaniel, Real-time
Characteization of Damage: Growth in Gr/Ep Laminates, J. Composite Materials,
10, 1976, p.182.
14. R. Prakash, Nondestructive Testing of Composites, Composites, 11, 1980, p.217.
142
5.5 EXERCISES
143
A subsurface delamination
ii.
An inclusion
iii.
Distribution of voids
iv.
A crack
v.
Improper bonding
vi.
Criticality of a flaw.
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
CHAPTER 6
MACROMECHANICAL BEHAVIOUR
6.1 INTRODUCTION
The heterogeneity in a composite material is introduced due to not only its biphase or in some cases multi-phase composition, but also laminations. This leads to a
distinctly different stress strain behaviour in the case of laminates. The anisotropy caused
due to fibre orientations and the resulting extension-shear and bending-twisting coupling
as well as the extension-bending coupling developed due to unsymmetric lamination add
to the complexities. A clear understanding of the constitutive equations of a composite
laminate is thus desirable before these are used in analysis and design of composite
structures. In this chapter, we first introduce to the readers the basic constitutive
equations for a general three-dimensional anisotropic material with and without material
symmetry, elastic constants and compliances and their relations to engineering constants,
as well as transformation laws for elastic constants and compliances for both three and
two-dimensional cases. We also discuss constitutive relations for several composite
materialsparticulate and short fibre composites, multidirectional fibre reinforced
composites, unidirectional lamina and general laminates as well as lamina strength
criteria.
6.2 THREE-DIMENSIONAL MATERIAL ANISOTROPY
For a three-dimensional elastic anisotropic body (Fig. 6.1), the generalized Hook's
law is expressed as
3
ij = Cijkl k l
(i, j = 1,2,3)
(6.1)
k =1 l =1
where ij and kl are the stress and strain tensors, respectively, and C ijkl are the elastic
constants. Here the indices i, j, k and l can assume values of 1, 2 and 3. This implies that
there may exist 34 = 81 independent elastic constants. However, it is known from the
theory of elasticity, that both stress tensor ij and strain tensor kl are symmetric. As
ij = ji , C ijkl = C jikl
and as kl = lk , C ijkl = C iflk
(6.2)
(6.3)
159
U=
1
C ijkl ij kl
2
(6.4)
U
= ij , then
ij
C ijkl = C klij
(6.5)
Equation 6.5 in conjunction with Eq. 6.3 finally reduce the total number of
independent elastic constants from thirty-six to twenty-one only. Such an anisotropic
material with twenty-one independent elastic constants is termed as triclinic. Now, using
the following contracted single index notations
11
1
22
2
33
3
= and
23 (= 23 ) 4
13 (= 13 ) 5
12 (= 12 ) 6
11
1
22
2
33
3
=
2 23 (= 23 ) 4
2 13 (= 13 ) 5
2 12 (= 12 ) 6
(6.6)
the constitutive relations for the general case of material anisotropy are expressed as
1 C11
2
3
=
4
5
6
or,
C12
C13
C14
C15
C22
C23
C24
C25
C 33
C34
C44
C35
C45
symmetric
{ 1 } = [C ij ]{ j } ;
C55
i, j = 1, 2,.,6
C16 1
C26 2
C36 3
=
C46 4
C56 5
C66 6
(6.7)
(6.8)
i, j =1, 2,..,6
(6.9)
(6.10)
160
There may exist several situations when the distribution and orientation of
reinforcements may give rise to special cases of material property symmetry. When there
is one plane of material property symmetry (say, the plane of symmetry is x3 = 0, i.e., the
rotation of 180 degree around the x3 axis yields an equivalent material), the elastic
constant matrix [ Cij ] is modified as
C11
Cij
=
one plane
of symmetry
( X = 0)
3
C12
C13
C22
C23
C33
0
C44
0
C45
symmetry
C55
C16
C26
C36
0
0
C66
(6.11)
Thus there are thirteen independent elastic constants, and the material is monoclinic. The
compliance matrix [Sij] for a monoclinic material may accordingly be written from Eq.
6.11 by replacing 'C ' with 'S '.
If there are three mutually orthogonal planes of symmetry, the material behaviour
is orthotropic. The elastic constant matrix [C ij ] is then expressed as
C11
[C ij ] orthotropic =
C12
C13
C22
C23
C33
0
0
0
0
C44
symmetry
C55
0
0
0
0
0
C66
(6.12)
Thus there are nine independent elastic constants. Correspondingly there exist nine
independent compliances.
Two special cases of symmetry, square symmetry and hexagonal symmetry, may
arise due to packing of fibres in some regular fashion. This results in further reduction of
independent elastic constant. For instance, if the fibres are packed in a square array (Fig.
6.2) in the X2X3 plane. Then
161
C11
C12
C12
C 22
C 23
C 22
C 44
0
C 66
symmetry
0
0
0
0
0
C 66
(6.13)
There exist now six independent elastic constants. Similarly, when the fibres are packed
in hexagonal array (Fig. 6.3),
C11
Cij
=
hexagonal array
C12
C12
C22
C23
C22
1
(C22 C23 )
2
symmetry
C66
C66
(6.14)
In the case of hexagonal symmetry, the number of independent elastic constants is
reduced to five only. The material symmetry equivalent to the hexagonal symmetry, is
also achieved, if the fibres are packed in a random fashion (Fig. 6.4) in the X2X3 plane.
This form of symmetry is usually termed as transverse isotropy. The [ Cij ] matrix due to
the transverse isotropy is the same as that given in Eq. 6.14. The compliance matrices
corresponding to Eqs. 6.12 through 6.14 can be accordingly written down. However,it
may be noted that in the case of rectangular array (Fig. 6.5), C12 C13, C22 C33 and C55
C66 (Eq. 6.13).
Material Isotropy
162
C11
Cij
=
isotropy
C12
C12
C11
C12
C11
1
(C11 C12 )
2
0
1
(C11 C12 )
2
symmetry
(C11 C12 )
2
(6.15)
The compliance matrix [Sij] for an isotropic material can be accordingly derived.
163
1
11
12
1
11
2 13
3
= 11
4
5
6
31
33
32
33
1
33
21
22
1
22
23
22
1
G23
symmetric
0
1
G13
0 1
2
0
3
0 4
5
0 6
1
G12
(6.16)
orthotropic { j }
(6.17)
Comparing Eqs. 6.16 and 6.17, we can express the compliances in terms of engineering
constants.
S11 =
1
1
1
; S22 =
; S33 =
;
11
22
33
S12 = S 21 =
S13 = S 31 =
S 23 = S 32 =
S 44 =
21
22
31
33
32
33
=
=
=
12
11
13
11
23
22
(6.18)
1
1
1
; S 55 =
; S 66 =
G23
G13
G12
The elastic constants can then be derived by inversion of the compliance matrix
i.e. [ Cij ] = [Sij]-1 and are given as follows:
2
C11 = 11 [1 ( 33 / 22 ) 23
]
C12 = C 21 = [ 22 12 + 33 13 23 ]
C13 = C 31 = 33 [ 12 23 + 13 ]
164
C 22 = 22 [1 ( 33 / 11 ) 132 ]
(6.19)
C 33 = 33 [1 ( 22 / 11 ) 122 ]
C44 = G23 ; C55 = G13 ; C66 = G12
where
2
( ) 1 = 1 2(33 / 11 )12 23 13 132 (33 / 11 ) 23
(33 / 22 ) 122 ( 22 / 11 ) (6.20)
In terms of engineering constants, the elastic constants and compliances for an isotropic
material are given by
and
C11 =
(1 )
; C12 =
(1 + )(1 2 )
(1 + )(1 2 )
S11 =
; S12 =
(6.21)
rr 1
2
zz 3
=
z 4
rz 5
r 6
and
(6.22)
S12
S13
S 22
S 23
S 33
S 44
0
S 55
symmetric
{i } = [ Sij ]{ j }
165
0 1
0 2
0 3
=
0 4
0 5
S 66 6
(6.23)
where
S11 =
1
1
1
; S22 =
; S33 =
;
rr
ZZ
S12 = S 21 =
S13 = S 31 =
S 23 = S 32 =
S 44 =
zr
zz
z
zz
rz
rr
rr
(6.24)
1
1
1
; S55 =
; S66 =
G z
Grz
Gr
(6.25)
or,
Q12
1 Q11
Q22
2 =
symm
6
Q16 1
Q26 2
Q66 6
(6.26)
{ i } = [Qij ]{ j },
i, j = 1,2,6
(6.27)
Where [Qij] are the reduced stiffnesses (elastic constants) for plane stress.
Similarly, in terms of compliances, the stress-strain relations are
S12
1 S11
S 22
2 =
symm
6
S16 1
S 26 2
S66 6
(6.28)
166
or,
{i } = [ S ij ]{ j },
i, j =1,2,6
(6.29)
For the case of two-dimensional orthotropy (Fig. 6.8) the stress-strain relations
are
1 Q11
2 = Q12
0
6
Q12
Q22
1 S11
2 = S12
0
6
S12
S 22
0
0 1
0 2
6
Q66
(6.30)
0 1
0 2
6
S 66
(6.31)
and
with
11
22
=
; Q22
1 12 21
1 12 21
= 12 22 = 21 11 ; Q66
= G12
Q12 = Q21
1 12 21
1 12 21
Q11 =
(6.32)
and
S11 =
1
1
1
=
; S 22
; S12 = S 21 = 21 = 12 ; S66 =
11
22
22
11
G12
(6.33)
, 22 , 12 , (or 21
) and G'12 are referred to
Note that the engineering constants 11
the orthotropic axis system X'1X'2 (i.e., the material axes).
If the elastic constants and compliances of a material are known with respect to a
given co-ordinate system, then the corresponding values with respect to any other
mutually perpendicular coordinates can be determined using laws of transformation.
These are explained in Appendix A.
6.7.1 Three-Dimensional Case
(6.34)
167
= [T] [C ij ] [T]T
(6.35)
(6.36)
[ S ij ] = [T ][ S ij ][T ]T
(6.37)
If the elements of [Qij ] and [Qij ] refer to the X1X2 and X'1X'2 coordinates (see
Eqs. 6.26 and 6.30 and Figs. 6.7 and 6.8), respectively, then transformation laws for
reduced elastic constants are obtained as follows:
(6.38)
(6.39)
where [T ] and [T ] are defined by Eqs. A.18 and A.19. The compliance matrices are
accordingly transformed using Eqs. 6.36 and 6.37.
Accordingly, from Eqs. 6.38 and A.18 it can be shown that
168
Q11 m 4
Q 4
22 n
2 2
Q12 m n
=
2 2
Q66 m n
Q16 m 3 n
Q26 mn 3
2m n
4m n
m
Q11
4m 2 n 2 Q22
m2n2
m4 + n4
2 2
2 2
2
2 2
2m n
(m n ) Q12
m n
mn 3 mn 3 m 3 n 2(mn 3 m 3 n) Q66
m 3 n m 3 n mn 3 2(m 3 n mn 3 )
n4
2m 2 n 2
4m 2 n 2
(6.40)
m
m n
2m n
S11
2 2
4
4
2 2
m n
m +n
m n S 22
2 2
2 2
2
2 2
4m n
(m n ) S12
8m n
2mn 3 2(mn 3 m 3 n) mn 3 m 3 n S 66
2m 3 n 2(m 3 n mn 3 ) m 3 n mn 3
n4
2m 2 n 2
2
m2n2
(6.41)
Note that m = cos and n = sin and [Qij ] and [ S ij ] are defined by Eqs. 6.32 and 6.33
, 22 , 12 (or 21
) and G'12
respectively, in terms of engineering constants 11
corresponding to principal material directions.
If transformation is required from one anisotropic material axis system (say X1X2
X3) to another anisotropic material axis system (say, X 1 X 2 X 3 ), then from Eqs. 6.38 and
A. 18 we can
[Q ij ] = [T ]T [Qij ][T ]
or,
Q11
Q12
Q16
Q12
Q22
Q26
Q16 m 2
n2
2mn Q11
2
2
Q26 = n
m
2mn Q12
Q66 mn mn m 2 n 2 Q16
or,
169
Q12
Q22
Q26
Q16 m 2
n2
mn
2
2
Q26 n
m
mn
Q66 2mn 2mn m 2 n 2
Q11
Q22
Q12
=
Q66
Q
16
Q26
Q11
m
2m n
4m n
4mn
4m n
Q22
m2n2
m4 + n4
4m 2 n 2
2(m 3 n mn 3 ) 2(mn 3 m 3 n) Q12
m2n2
2m 2 n 2
(m 2 n 2 ) 2
2(m 3 n mn 3 ) 2(mn 3 m 3 n) Q66
mn 3 mn 3 m 3 n 2(mn 3 m 3 n) m 4 3m 2 n 2
3m 2 n 2 n 4 Q16
m 4 3m 2 n 2 Q26
m 3 n m 3 n mn 3 2(m 3 n mn 3 ) 3m 2 n 2 n 4
m4
4
n
m 2 n 2
2 2
m n
m3n
3
mn
n4
2m 2 n 2
4m 3 n
4m 2 n 2
4m 3 n
(6.42)
Similarly, using Eqs. 6.36 and A.19 one can write
[ S ij ] = [T ]T [ S ij ][T ]
or,
S11
S22
S
12
=
S66
S
16
S26
m4
4
n
m2n2
2 2
4m n
2m 3 n
3
2mn
S11
m n
2m n
2mn
2m n
m
S 22
2 2
4
4
2 2
3
3
3
3
m n
m +n
m n mn
mn m n S12
m n
2 2
2 2
2
2 2
3
3
4m n
(m n ) 4(m n mn ) 4(mn 3 m 3 n) S 66
8m n
3m 2 n 2 n 4 S16
2mn 3 2(mn 3 m 3 n) mn 3 m 3 n m 4 3m 2 n 2
m 4 3m 2 n 2 S 26
3m 2 n 2 n 4
2m 3 n 2(m 3 n mn 3 ) m 3 n mn 3
n4
2m 2 n 2
2
m2n2
2
2m 3 n
3
2m 3 n
3
(6.43)
6.8 PARTICULATE AND SHORT FIBRE COMPOSITES
170
bundles of diagonal fibres f4, f5. We consider here an integrated multidirectional fibre
reinforced composite moder which contains n number of unidirectional fibre composite
blocks that are oriented in n arbitrary directions with respect to a three-dimensional
reference axes X1X2 X3. Each unit block may have different fobre volume fractions. This
arrangement makes n number of material axis systems, and therefore yield n sets of
direction cosines between n material axis systems and the reference axes X1X2 X3. For
example, Figure 6.11b represents the orientation of the material axis system for the ith
block. The corresponding transformation matrices [T ]i and [T ]i can then be written
down using Eqs. A.8 and A.13, respectively.
The material behaviour for each block with respect to its axes is orthotropic. The
elastic constants for the ith block are then given as
C11
C
12
C
[C ij ]i = 13
0
0
C12
C 22
C13
C 23
C 23
C 33
0
0
0
0
C 44
C 55
0
0
0
0
0
i
C 66
(6.44)
The effective elastic constants for the n-directional fibre reinforced composite are then
determined by averaging the transformed properties as follows:
[C ij ] =
1 n
( [T ]Ti [C ij ]i [T ]i
n i =1
(6.45)
1 n
(V f ) i
n i =1
(6.46)
172
Figure 6.12a depicts a unidirectional lamina where parallel, continuous fibres, are
aligned along the X'1 axis (fibre axis or longitudinal direction). The X'2 axis (transverse
direction) is normal the fibre axis. The axes X'1X'2 are referred as material axes. The
material axes are oriented counter clockwise by angle with respect to the reference
axes X1X2. The angle (also referred as fibre angle) is considered positive when
measured counterclockwise from the X1 axis. This type of unidirectional lamina is termed
as off-axis lamina. An off-axis lamina behaves like an anisotropic two-dimensional
body, and the stress-strain relations, given by Eqs. 6.26 through 6.29, can be used for the
present case.
When the material axes coincide with the reference axes (i.e., =0), as shown in
Fig. 6.12b, the lamina is termed as on-axis lamina and its behaviour is orthotropic in
nature. The stress-strain relations are defined by Eqs. 6.30 and 6.31.
, 22 , 12 , (or 21
) and G'12 are usually known, as
The engineering constants 11
these can be determined either by using micromechanics theories (chapter 4) or by
characterization tests (chapter 5). Using these engineering constants, the reduced
stiffnesses [Qij ] and compliances [ S ij ] are then determined for an orthotropic lamina with
the help of Eqs. 6.32 and 6.33. The transformed reduced stiffnesses [Qij ] and [ S ij ] can
now be evaluated employing Eqs. 6.40 and 6.41. The stiffness [Qij ] and compliances
[ S ij ] for three composite systems are computed for various fibre orientations and are
listed in Tables 6.1 and 6.2. Typical variations of transformed properties [Qij ] and [ S ij ]
with change in the fibre angle are illustrated in Figs. 6.13 and 6.14. Such plots aid to
the basic understanding of the stiffness behaviour of an off-axis lamina with different
fibre orientations. Note that the case =0 corresponds to an on-axis lamina.
173
behaviour is orthotropic and the lamina may be termed as on-axis bidirectional lamina.
If the X1' X2' plane rotates by an angle with respect to the X1X2 axes (Fig. 6.15a), then
the oriented lamina behaves as an anisotropic material and it can be identified as an offaxis bidirectional lamina can also be treated as a two-dimensional problem and its
elastic properties can be determined in an usual manner as discussed in sections 6.6 and
6.10. It may be mentioned that the anisotropy and stiffness behaviour of a bidirectional
lamina can be greatly controlled by varying the types of fibres (say, carbon fibre along
the X1' direction and glass fibre along the X2' direction) and volume fractions of fibres
(Vf) in both directions. When the fibres and Vf are same in both directions, then
E'11 = E'22 and the material behaviour is square symmetric. Note that a square symmetric
material is different from an isotropic material.
We consider here a general thin laminate of thickness h (Fig. 6.16). The X3 axis is
replaced here by the z axis for convenience. The laminate consists of n number of
unidirectional and/or bidirectional laminae, where each lamina may be of different
materials and thicknesses and have different fibre orientations ( ). A thin general
laminate is essentially a two-dimensional problem, but cannot be treated as a twodimensional plane stress problem as has been done for a unidirectional lamina. The
existence of extension bending couling causes bending, even if the laminate is subjected
to inplane loads only. Therefore, thin plate bending theories are employed in derivation
of constitutive relations. We assume that Kirchhoff 's assumptions related to the thin plate
bending theory are applicable in the present case.
Let u10, u20 and w are the mid-plane displacements, and w is constant through the
thickness of the lamina. Then the mid-plane strains are given by
10 =
u10
u 0
, 02 = 2
x1
x2
and 60 =
u10 u20
+
x2 x1
(6.47)
and the curvatures, which are constant through the thickness of the laminate, are
k1 =
2w
2w
2w
=
,
k
and
k
2
2
6
x12
x22
x1 x2
(6.48)
174
(6.49)
Q16 1
Q26 2
Q66 z 6 z
Q12
Q22
Q26
Q11
= Q12
Q16
Q16 10 k1
Q26 02 + z k 2
Q66 z 06 k 6
Q12
Q22
Q26
(6.50)
The stress and moment resultants (Fig. 6.17) are evaluated per unit length of the
laminate as follows:
N1 h / 2 1
M 1 h / 2 1
N 2 = 2 dz and M 2 = 2 z dz
N h / 2
M h / 2
6
6
6
6
Thus,
h/2
N1 =
1dz =
h / 2
A12
10
A16 ] 02 + [ B11
0
6
Q dz and B =
B12
k1
B16 ] k2
k
6
h/2
Q z dz
h / 2
h / 2
M1 =
Q12
11
10 k1
Q16 ] 02 + z k2 dz
0 k
6 6
h/2
h/2
[Q
h / 2
= [ A11
where =
h/2
1 z dz =
h / 2
= [B11
h/2
[Q
11
Q12
h / 2
B12
10
B16 ]02 + [D11
0
3
10 k1
Q16 ] 02 + z k2 z dz
0
6 k6
D12
175
k1
D16 ]k 2
k
6
(6.51)
h/2
where B =
h/2
Q z dz and
D=
h / 2
Q z 2 dz
h / 2
Proceeding in a similar manner, all stress and moment resultants can be expressed as
listed below:
1 A11
A
2 12
6 A16
=
1 B11
2 B12
6 B16
A12
A16
B11
B12
A22
A26
B12
B 22
A26
A66
B16
B 26
B12
B 22
B16
B 26
D11
D12
D12
D 22
B 26
B 66
D16
D 26
h/2
Q ij (1, z, z ) dz;
2
B16 10
B 26 02
B66 06
D16 k 1
D 26 k 2
D66 k 6
i, j = 1, 2, 6
(6.52)
(6.53)
h / 2
Equation 6.52 represents the constitutive relations for a general laminate, and Aij,
Bij, and Dij are the inplane, extension bending coupling and bending stiffnesses,
respectively. Note that all these stiffnesses are derived for a unit length of the laminate.
The elastic properties of each lamina are generally assumed to be constant through its
thickness, as these laminae are considered to be thin. Then Aij, Bij, and Dij are
approximated as
n
ij = (Qij ) k ( z k z k 1 )
k =1
Bij =
1 n
(Qij ) k ( zk2 zk21 )
2 k =1
Dij =
1 n
(Qij ) k ( zk3 zk31 )
3 k =1
(6.54)
From Eq. 6.52, it is seen that there exist several types of mechanical coupling in a
general laminate. These are grouped together as follows:
Extension Shear
: A16, A26
Extension Bending
Extension Twisting
: B16 , B26
Shear Bending
: B16 , B26
Shear Twisting
B66
176
Bending Twisting
D16 , D26
Biaxial Extension
A12
Biaxial Bending
D12
As stated earlier, the coupling terms Bij occur due to unsymmetry about the middle
surface of a laminate. However, all terms containing suffices '16 ' and '26 ' are resulted
due to anisotropy caused by the fibre orientation other than 00 and 900. Those
containing suffices '12 ' are due to Poisson's effect. Although a heneral unsymmetric
laminate contains all coupling terms, there are several laminates where some of these
may vanish. These are listed in Table 6.3. There are several important points that are to
be noted here. The first two laminates (serial nos. 1 and 2) which are christened as offaxis laminate and on-axis laminate; respectively are essentially paralles ply laminates
where all laminae in a laminate have the same fibre orientation and therefore are stacked
parallel to each other. These are, in fact, similar to unidirectional laminae. For a
symmetric balanced angle-ply laminate D16 and D26 do not vanish, although A16 = A26 =
0. The only coupling effect that appears in an anti-symmetric cross-ply laminate is the
extension-bending coupling due to presence of B11and B22 and note that B22 = - B11. But
the existence of B16 and B26 cause an antisymmetric angle-ply laminate to experience
extension-twisting coupling. Note also that extension-bending coupling is predominant
for an unsymmetric cross-ply laminate.
The mechanical coupling, as discussed above, influences the deformation
behaviour of a laminate to a great extent. This can be better understood by examining the
deformed shapes of a couple of laminates as illustrated in Figs. 6.18 through 6.20. Here
the dotted lines represent the undeformed shape and the firm lines, deformed shapes.
Consider first a simple off-axis laminate (or unidirectional lamina), subjected to an
inplane stress resultant N1 (Fig.6.18a) and an out-of-plane moment resultant M1 (Fig.
6.18b). We know from Eq. 6.52 and Table 6.1 (Bij=0) that
1 = 11 1 + 12 2 + 16 6
(6.55)
Thus, as illustrated in Fig. 6.18a, it is noted that a simple tension causes not only
extension and contraction, but also shearing of the laminate. While the extension and
contraction are due to A11 and A12, respectively and the inplane shear deformation is due
to presence of A16. This characteristic behaviour is seen especially in an anisotropic (offaxis) laminate. The shear deformation vanishes, if A16 = 0, as in the case of an orthotropic
177
(on-axis) laminate (serial no.2 of Table 6.1). Similarly, as can be seen in Fig. 6.18b, a
simple bending due to M1 has resulted not only longitudinal bending (due to D11) and
transverse bending (due to D12), but also twisting (due to D16).
Figure 6.19 describes the deformation behaviour of an antisymmetric cross-ply
laminate. The extension-bending coupling due to B11 and B22 can be clearly observed. In
Fig. 6.19a a simple inplane tension is found to introduce bending in the laminate.
Conversely, a simple bending causes extension of the laminate, a shown in Fig. 6.19b.
Table 6.4 provides the stiffnesses [Aij], [Bij]and [Dij] for various stacking
sequences of carbon/epoxy composites. The [Qij] values given in Table 6.1 have been
used to compute the above stiffnesses.
1 S11
2 = S12
S
6 16
S12
S 22
S 26
S16 1 1e
S 26 2 + e2
S 66 6 e6
(6.56)
with
1e 1H 1T
e H T
2 = 2 + 2
e H T
6 6 6
(6.57)
and
178
1H
1
H
2 = C 2
H
6
6
1T
T
2 = T
T
6
and
1
2
6
(6.58)
Inversion of Eq. 6.56 yields (see also Eq. 6.26), at any distance z (Fig. 6.16),
1 Q11
2 = Q12
Q
6 z 16
Q16
Q26
Q66 Z
Q12
Q22
Q26
1e
e2
6e
(6.59)
z
1 A11
A
2 12
6 A16
=
1 B11
2 B12
6 B16
A12
A16
B11
B12
A22
A26
A26
A66
B12
B16
B22
B26
B12
B16
D11
D12
B22
B26
B26
B66
D12
D16
D22
D26
B16 10 1e
B26 02 e2
B66 06 6e
+
D16 k1 1e
D26 k 2 e2
D66 k 6 e6
(6.60)
2 = Q12
e h / 2 Q
16
6
Q12
Q22
Q26
Q16 1e
Q26 e2 dz
Q66 z e6
z
179
(6.61)
1e h / 2 Q11
e
2 = Q12
e h / 2 Q
16
6
Q12
Q22
Q26
Q16 1e
Q26 e2 z dz
Q66 z 6e
(6.62)
These expansional force resultants and moments may considerably influence the
deformation behaviour of a laminate.
Isotropic materials do not have any preferential direction and in most cases tensile
strength and compressive strength are equal. The shear strength is also dependent on the
tensile strength. A strength criterion for an isotropic lamina is, therefore, based on stress
components, 1, 2 and 6 for a two-dimensional problem and a single strength constant
i.e., ultimate strength X. An orthotropic lamina (Fig. 6.8), on the other hand, exhibits five
independent strength constants e.g., tensile strength X'11t a dcompressive strength X'11c
along the X'1 direction; tensile strength X'22t and compressive strength X'22c along the X'2
direction and inplane shear strength X'12. Hence a strength criterion for a twodimensional orthotropic lamina should involve the stress components '1, '2 and '6 and
strength constants X'11t, X'11c, X'22t X'22c and X'12. We present here a few important
strength criteria that are commonly used to evaluate the failure of an orthotropic lamina.
Maximum Stress Criterian
A lamina is assumed to fail, if any of the following relations is satisfied
(6.63)
6 12
It is assumed that inplane shear strengths are equal under positive or negative shear load.
Maximum Strain Criterian
A lamina fails, if any of the following is satisfied
180
(6.64)
Note that the addition of suffix 'u' in strain components indicates the corresponding
ultimate strains. The ultimate shear strains are also assumed to be equal under positive or
negative shear load. If a material behaves linearly elastic till failure, the ultimate strains
can be related to ultimate strength constants as follows:
t / 11
; 2u t = 22t / 22
1u t = 11
c / 11
; 2u c = 22c / 22
1u c = 11
(6.65)
/ G12
6u = 12
Tsai-Hill Criterion
2G 1 3 2 F 2 3 + 2 L( 4 ) 2 + 2 M ( 5 ) 2 + 2 N ( 6 ) 2
(6.66)
Assuming that normal stresses 1 , 2 and 3 an dshear stress 6 act independently and
) 2 ; F + H = 1 /( 22 ) 2 ; F + G = 1 /( 33 ) 2 ; 2 N = 1 /( 12
)2
G + H = 1 /( 11
(6.67)
1
1
1
+
2
2
)
( 11
( 22 )
( 33 ) 2
2G =
1
1
1
+
2
2
)
( 11
( 33 )
( 22 ) 2
2F =
1
1
1
+
2
2
)2
( 22 )
( 33 )
( 11
(6.68)
Assuming transverse symmetry X'22 = X'33 and two-dimensional plane stress case (3 = 4
= 5 =0), Eq. 6.66 reduces to
(G + H )( 1 ) 2 + ( F + H )( 2 ) 2 2 H 1 2 + 2 N ( 6 ) 2 = 1
or,
2
1
2
1 2 6
+ 2 + =1
( 11 )
11
22
12
181
(6.69)
When 1 , 2 or both are tensile or compressive, Eq. 6.69 can be used by substituting the
corresponding tensile or compressive strength constants in it. Thus, if 1 is tensile, X'11 =
X'11t , and if 2 is compressive, X'22= X'22c and so on.
Tsai-Hill / Hoffman Criterion
(6.70)
(6.71)
(6.72)
C4 =
1
1
1
; (C2 + C3 ) =
t
c
t
11
c
11
11
11
(6.73)
C5 =
1
1
1
; (C1 + C3 ) =
t
c
t
22 22
22 22c
(6.74)
C6 =
1
1
1
; (C1 + C2 ) =
t
c
t
33 33
33 33c
(6.75)
Now, assuming 22 = 33 , we derive from the above the following relations for C1, C2
and C3:
C1 =
1
1
c
t 11
c
22 2 11
(6.76)
1
t 11
c
2 11
(6.77)
t
22
C2 = C3 =
182
C9 =
1
( X 12 ) 2
(6.78)
( 1) 2
( 2 ) 2
1 2
1
1
1
1
+
+ ( t c ) 1 + ( t c ) 2 + ( 6 ) 2 = 1
t
c
t
c
t
c
11
11
11
22 22
11
11
11
22 22
12
(6.79)
(6.80)
Considering that the positive or negative inplane shear stress 6 should not affect the
results, the terms F16 1 6 , F26 2 6 and F6 6 should vanish. Hence Eq. 6.80 reduces
to
(6.81)
Now applying independently tensile and compressive normal stresses 1 and 2 , and
inplane shear stresses 6 , and substitution of 1 =X'11t - 1 =X'11c, 2 =X'22t , - 2 = X'22c
and 6 =X'12 in Eq. 6.81 yields
F11 =
1
1
1
, F1 = t C
C
11
11
11
F22 =
1
1
1
, F2 = t C
C
22 22
22 22
F66 =
1
)2
( 12
t
11
(6.82)
Employing the von Mises plane stress analogy, the remaining interaction coefficient F12
can be defined
183
F12 =
1
2( 22t 22C )1/ 2
t
11
(6.83)
C
11
Combining Eqs. 6.81-6.83, the Tsai-Wu criterian takes the following form:
( 1) 2
( 2 ) 2
1 2
+
+ ( 6 )2
t
c
t
c
t
c 1/ 2
t
c
11
( 11
11
22 22 )
11
22 22
12
1
1
1
1
( t c ) 1 + ( t c ) 2 = 1
11
11
22 22
(6.84)
It is to be mentioned that the Tsai-Wu criterion (Eq. 6.84) accounts for interaction of
stress components as well as both tensile and compressive strength constants and shear
strength and is considered as a reasonably accurate and consistent representation of
failure of an orthotropic lamina under biaxial stresses. The Tsai-Hill criterion (Eq. 6.69)
is also very popular with composite structural designers.
184
Table 6.1: Stiffnesses [Qij ] and [Qij ] for three unidirectional composites (GPa)
Q11
Q22
Q12
Q66
Kelvar/Epoxy
91.87
4.03
1.41
2.26
Carbon/Epoxy
133.94
8.32
2.16
3.81
Boron/Polyimide
242.39
14.93
3.88
5.53
Material
Material
Q11
Q22
Q12
Q66
Q16
Q26
91.87
4.03
1.41
2.26
0.00
0.00
30
54.15
10.23
17.17
18.02
28.12
9.92
45
26.93
26.93
22.42
23.27
21.96
21.96
60
10.23
54.15
17.17
18.02
9.92
28.12
90
4.03
91.87
1.41
2.26
0.00
0.00
133.94
8.32
2.16
3.81
0.00
0.00
30
79.53
16.72
25.17
26.82
40.48
13.92
45
40.46
40.46
32.84
34.48
31.40
31.40
60
16.72
79.53
25.17
26.82
13.92
40.48
90
8.32
133.94
2.16
3.81
0.00
0.00
Boron/
242.39
14.93
3.88
5.53
0.00
0.00
Plyimide
30
142.88
29.15
46.53
48.17
73.87
24.62
45
71.80
71.80
60.74
62.39
56.87
56.87
60
29.15
142.88
46.53
48.17
24.62
73.87
90
14.93
242.39
3.88
5.53
0.00
0.00
(degree)
Kelvar/
Epoxy
Carbon/
Epoxy
185
Material
S11
S 22
S12
S 66
Kelvar/Epoxy
10.94
249.75
-3.83
443.49
Carbon/Epoxy
7.50
120.66
-1.95
262.47
Boron/Polyimide
4.14
67.27
-1.08
180.96
Material
S11
S 22
S12
S 66
S16
S 66
10.94
249.75
-3.83
443.46
0.00
0.00
30
103.48
222.88
-36.66
312.13
-141.32
-65.50
45
174.12
174.12
-47.61
268.35
-119.40
-119.40
60
222.88
103.48
-36.66
312.13
-65.50
-141.32
90
249.75
10.94
-3.83
443.46
0.00
0.00
7.50
120.66
-1.95
262.47
0.00
0.00
30
60.24
116.82
-26.40
164.66
-77.23
-20.76
45
96.68
96.68
-34.55
132.05
-56.58
-56.58
60
116.82
60.24
-26.40
164.66
-20.76
-77.23
90
120.66
7.50
-1.95
262.47
0.00
0.00
Boron/
4.14
67.27
-1.08
180.96
0.00
0.00
Plyimide
30
40.06
71.63
-21.21
100.42
-50.59
-4.08
45
62.56
62.56
-27.93
73.57
-31.56
-31.56
60
71.63
40.06
-21.21
100.42
-4.08
-50.59
90
67.27
4.14
-1.08
180.96
0.00
0.00
(degree)
Kelvar/
Epoxy
Carbon/
Epoxy
186
Elastic behaviour
Stiffnesses
I. Symmetric Laminates
1. Off-axis laminate
(all plies oriented
at )
anisotropic
and uncoupled
2. On-axis laminate
(all plies oriented either
00 or 900)
orthotropic
and uncoupled
3. Symmetric cross-ply
(odd number of
00 / 900 / 00, etc. plies)
specially
orthropic and
uncoupled
4. Symmetric angle-ply
(odd number of /- / ,
anisotropic and
uncoupled
anisotropic and
uncoupled
etc. plies)
5. Symmetric balanced angle
ply ( /- /- / , etc. plies)
6. Antisymmetric cross-ply
(even number of
00 / 900 / 00/900, etc. plies)
orthotropic and
partly coupled
7. Antisymmetric angle-ply
(even number of
( /- / /- , etc. plies)
anisotropic and
partly coupled
A16= A26=B11=B22
B12= B66= D16= D26=0
rest of Aij, Bij and Dij are
finite.
8. Unsymmetric cross-ply
(irregular stacking of
00 or 900 plies)
orthotropic but
coupled
9. General unsymmetric
laminate
anisotropic and
strongly coupled
187
Bij
for carbon/epoxy composite laminates
Dij
Aij
Table 6.4: Stiffneses
Bij
[Dij], GPa-mm3
1. 00 / 900 / 00 laminates
0.00
0.00
0.00 0.00
368.28 8.66
8.66 200.78 0.00
0.00
0.00 0.00
0.00
0.00 15.24 0.00
0.00 0.00
0.00
0.00 689.55 11.54 0.00
0.00
0.00
0.00
0.00 11.54 69.20 0.00
0.00
0.00
0.00
0.00 20.32
0.00
2. 450 / -450 / 450 laminate
0.00
0.00
0.00
161.83 131.35 41.87
131.35 161.83 41.87
0.00
0.00
0.00
0.00
0.00 215.78 175.14 155.09
0.00
0.00
0.00
0.00 175.14 215.78 155.09
0.00
0.00 155.09 155.09 183.92
0.00
3. 450 /-450 /450 / 450 laminate
0.00
0.00
0.00
161.83 131.35 0.00
131.35 161.83 0.00
0.00
0.00
0.00
0.00
0.00 137.94 0.00
0.00
0.00
0.00
0.00 215.78 175.14 125.62
0.00
0.00
0.00
0.00 175.14 215.78 125.62
0.00
0.00 125.09 125.09 183.92
0.00
4. 00 /900 / 00 / 900 laminate
284.83
8.66
0.00
125.62
0.00
0.00
8.66
284.53
0.00
0.00
125.62
0.00
0.00
0.00
15.24
0.00
0.00
0.00
125.62
0.00
0.00
379.37
11.54
0.00
188
0.00
125.62
0.00
11.54
379.37
0.00
0.00
0.00
0.00
0.00
0.00
20.32
0.00
0.00
137.94 62.81 62.81 0.00
0.00
0.00
62.81 215.78 175.14
0.00
0.00
0.00
0.00
62.81 175.14 215.78
0.00
0.00
183.92
62.81 62.81 0.00
6. 00 /900 /00 / 00 laminate
0.00 62.81
0.00
0.00
410.15 8.66
8.66
158.91 0.00
0.00 62.81 0.00
0.00
0.00 15.24 0.00
0.00
0.00
0.00
0.00 672.49 11.54
0.00
62.81
0.00 62.81 0.00 11.54
86.26
0.00
0.00
0.00
0.00
0.00
20.92
0.00
6.15 BIBLIOGTAPHY
1. S.P. Timoshenko and J.N. Goodier, Theory of Elasticity, McGraw Hill, N.Y.,
1970.
2. Y.C. Fung, Foundations of Solid Mechanics, Englewood Cliffs, N.J., 1965.
3. S.G. Lekhnitskii, Theory of Elasticity of an Anisotropic Body, MIR Publ.
Moscow, 1981.
4. J.C, Halpin, Primer or Composite Materials: Analysis, Technomic Publ. Co., Inc.
Lancaste, 1984.
5. R.M. Christensen, Mechanics of Composite Materials, Wiley Interscience, N.Y.,
1979.
6. Z. Hashin and C.T. Herakovich (Eds.), Mechanics of Composite Materials-Recent
Advances, Pergamon Press, N.Y.,1983.
7. S.W. Tsai and H.T. Hahn, Introduction to Composite Materials Technomic Publ.
Co., Inc., Lancaster,1980.
189
6.16 EXERCISES
[ S ij ] = [T ]T [ S ij ][T ]
6. Assume properties given in Table 4.4 for Kevlar/epoxy and
carbon/epoxy/composites and determine [Aij], [Bij] and [Dij] for a
[0 02 K / 45 02 C / 0 02 K ] hybrid laminate (thickness 4 mm).
7. Make a critical assessment of various lamina failure theories.
8. Derive expressions for Tsai-Hill and Tsai-Wu strength criteria.
190
191
192
193
194
195
196
197
198
199
200
201
202
203