INTRODUCTION

HISTORY
The development of mankind is defined in terms of advances in materials i.e. the stone age, the
bronze age, and the iron age. The present era of material belongs to the composite materials
because of its lighter weight, higher strength, corrosion resistance, ease to shape and durability.
The composites are not new to the mankind; it has a history of more than 3000 years. In ancient
Egypt, people used to build walls from the bricks made of mud with straw as reinforcing
component. Another important application of composites can be seen around 1200 AD from
Mongols. Mongolians invented a bow made up of composites. Using a combination of animal
glue, bone and wood, bows were pressed and wrapped with birch bark. The word composites
derived from the Latin word compositus, which means put together signifying something made
by putting together different parts or materials. In general, composites are materials which
consist of two or more physically distinct and mechanically separable components, existing in
two or more phases. The mechanical properties of composites are superior to those of its
individual constituents, and in some cases may be unique for specific properties. Usually,
composites have two phases i.e. continuous and discontinuous. The discontinuous phase is
usually stronger and harder than the continuous phase and is called the reinforcement, and
continuous phase is termed as the matrix. Composites can be classified in two ways i.e. based on
the reinforcement used (particle reinforced and fiber reinforced) and based on the matrix used
(i.e. metal matrix, polymer matrix and ceramic matrix). Composite materials have a wide range
of applications. They possess applications in buildings and public works (chimneys, housing
cells, door panel, windows, partitions, swimming pools, furniture and bathrooms); electrical and
electronics (insulation for electrical construction, armor, boxes, covers, cable tracks, radomes,
antennas, tops of television towers, and wind.
1.1 DEFINITION OF COMPOSITE
The most widely used meaning is the following one, which has been stated by Jartiz Composites
are multifunctional material systems that provide characteristics not obtainable from any discrete
material. They are cohesive structures made by physically combining two or more compatible
materials, different in composition and characteristics and sometimes in form.
The weakness of this definition resided in the fact that it allows one to classify among the
composites any mixture of materials without indicating either its specificity or the laws which
should given it which distinguishes it from other very banal, meaningless mixtures.
Kelly very clearly stresses that the composites should not be regarded simple as a combination
of two materials. In the broader significance; the combination has its own distinctive properties.
In terms of strength to resistance to heat or some other desirable quality, it is better than either of
the components alone or radically different from either of them.
Beghezan defines as The composites are compound materials which differ from alloys by the
fact that the individual components retain their characteristics but are so incorporated into the
composite as to take advantage only of their attributes and not of their short comings, in order to
obtain improved materials.

Van Suchetclan explains composite materials as heterogeneous materials consisting of two or

more solid phases, which are in intimate contact with each other on a microscopic scale. They
can be also considered as homogeneous materials on a microscopic scale in the sense that any
portion of it will have the same physical property.

PROPERTIES OF COMPOSITE
composites are extremely versatile products - their benefits being:
HighStrength to Weight Ratio
Fibre composites are extremely strong for their weight. By refining the laminate many
characteristics can be enhanced. A common laminate of say 3 mm Chopped strand mat, is quite
flexible compared to say a 3 mm ply. However it will bend a long way more than the ply before
yeilding. Stiffness should not be confused with Strength. A carbon fibre laminate on the other
hand, will have a stiffness of many times that of mild steel of the same thickness, increased
ultimate strength.
Lightweight
A standard Fibreglass laminate has a specific gravity in the region of 1.5, compared
to Alloy of 2.7 or steel of 7.8. When you then start looking at Carbon laminates,
strengths can be many times that of steel, but only a fraction of the weight . A DVD
case lid was produced using carbon fibre to reduce the case's overall weight so that
it could be carried as cabin baggage whilst travelling, and for improved security. It
was used by support crew for the All Blacks during their 1999 Rugby World Cup
campaign
Fire Resistance

The ability for composites to withstand fire has been steadily improving over the years. There is
two types of systems to be considered:Fire Retardent - are self extinguishing laminates, usually made with chlorinated resins and
additives such as Antimony trioxide. These release CO2 when burning so when the flame source
is removed, the self extinguish.
.
Fire Resistant - More difficult and made with the likes of Phenolic Resins. These are
difficult to use, are cured with formaldehyde, and require a hi degree of post curing to achieve
true fire resistance. Other materials are also becoming more readily available to be used as
intumescent layers, which expand and blanket the surface, preventing spread of flame. There is a
paint on coating usually applied to the back of the product laminate, plus a thin fibre film to go
under the Gelcoat.
Electrical

Fibre glass Developments Ltd produced the Insulator Support straps for the Tranz Rail main
trunk electrification. The straps, although only 4mm thick, meet the required loads of 22kN, as
well as easily meeting insulation requirements
Chemical

Weathering Resistance

Composite products have good weathering properties and resist the attack of a wide range of
chemicals. This depends almost entirely on the resin used in manufacture, but by careful
selection resistance to all but the most extreme conditions can be achieved. Because of this,
composites are used in the manufacture of chemical storage tanks, pipes, chimneys and ducts,
boat
hulls
and
vehicle
bodies.
.
FDL manufactured architectural panels for the construction of the Auckland Marine Rescue
Centre. Composite panels were chosen because of their ability to withstand salty sea side
conditionswithout
corrosion.
Colour
Almost any shade of any colour can be incorporated into the product during
manufacture by pigmenting the gelcoat used. Costs are therefore reduced by no
further finishing or painting. Soluble dyes can be used if a translucent product is
desired.
We do not however, recommend dark colours. These produce excessive heat on the
surface which can lead to the surface deteriorating and showing print through,
where the Resn matrix cures more and shrinks, bringing the fibres to the surface. In
extreme
cases
delamination
can
occur.
Translucency
Polyester resins are widely used to manufacture translucent mouldings and sheets.
Light
transmission
of
up
to
85%
can
be
achieved
Design

Flexibility

Because of the versatility of composites, product design is only limited by your

imagination.
Low

Thermal

Conductivity

Fibreglass Developments has been involved in the development and production of

specialised meat containers which maintain prime cuts of chilled meat at the correct
temperature for Export markets. They are manufactured using the RTM process,
with
special
reinforcing
and
foam
inserts.
Manufacturing

Economy

Fibreglass Developments produces several models of fuel pump covers for Fuelquip.
Fibreglass is an ideal material for producing items of this type for many reasons,
including
being
very
economical.

Because of its versatile properties, fibreglass can be used in many varied

applications.

CLASSIFICATION OF COMPOSITES
Composite material is a material composed of two or more distinct phases (matrix phase and
dispersed phase) and having bulk properties significantly different form those of any of the
constituents.

Matrix phase

The primary phase, having a continuous character, is called matrix. Matrix is usually more
ductile and less hard phase. It holds the dispersed phase and shares a load with it.

Dispersed (reinforcing) phase

The second phase (or phases) is embedded in the matrix in a discontinuous form. This secondary
phase is called dispersed phase. Dispersed phase is usually stronger than the matrix, therefore it
is sometimes called reinforcing phase.

TYPES OF COMPOSITE MATERIALS

The composite materials are broadly classified into the following categories as
shown in Figure-1.1

1.Fiber-reinforced composites
Reinforced-composites are popularly being used in many industrial applications because of their
inherent high specific strength and stiffness. Due to their excellent structural performance, the
composites are gaining potential also in tribological applications. Fiber reinforced composites
materials consists of fiber of high strength and modulus bonded in to a matrix with distinct
interfaces (boundary) between them [4,5]. In this form both fibers and matrix retain their
physical and chemical identities. Yet they produce a combination of properties that cannot be
achieved with either of the constituents acting alone. In general, fibers are the principal load
carrying candidates, while the surrounding matrix keeps them in the desired location and
orientation [6, 7]. A Fibrous composite can be classified into two broad groups: continuous
(long) fiber composite and discontinuous (short) fiber composite.
2.Continuous

or long fiber composite

Continuous or long fibre composite consists of a matrix reinforced by a dispersed phase in the
form of continuous fibers. A continuous fiber is geometrically characterized as having a very
high length-to- diameter ratio. They are generally stronger and stiffer than bulk material. Based
on the manner in which fibers are packed within the matrix, it is again subdivided in to two
categories: (a) unidirectional reinforcement and (b) bidirectional reinforcement. In unidirectional

reinforcement, the fibres are oriented in one direction only where as in bidirectional
reinforcement the fibres are oriented in two directions either at right angle to one another (crossply), or at some desired angle (angle-ply). When fibres are large and continuous, they impart
certain degree of anisotropy to the properties of the composites particularly when they are
oriented. Multi-axially oriented continuous fiber composites are also display near isotropic
properties.

3.Discontinuous or short fiber composite

Short-fiber reinforced composites consist of a matrix reinforced by a dispersed phase in form of
discontinuous fibers (length < 100* diameter). The low cost, ease of fabricating complex parts,
and isotropic nature are enough to make the short fiber composites the material of choice for
large-scale production. Consequently, the short-fiber reinforced composites have successfully
established its place in lightly loaded component manufacturing. Further the discontinuous fiber
reinforced composite divided into: (a) biased or preferred oriented fiber composite and (b)
random oriented fiber composite. In the former, the fibers are oriented in predetermined
directions, whereas in the latter type, fibers remain randomly. The orientation of short fibers can
be done by sprinkling of fiber on to given plane or addition of matrix in liquid or solid state
before or after the fiber deposition.The discontinuities can produce a material response that is
anisotropic, but the random reinforcement produces nearly isotropic properties.

4.Laminate Composites
Laminate Composites are composed of layers of materials held together by matrix. Generally,
these layers =are arranged alternatively for the better bonding between reinforcement and the
matrix. These laminates can have uni- directional or bi-directional orientation of the fiber
reinforcement according to the end use of the composite. The different types of composite
laminates are: unidirectional, angle-ply, cross-ply and symmetric laminates. A hybrid laminate
can also be fabricated by the use of different constituent materials or of the same material with
different reinforcing pattern. In most of the applications of laminate composites, man-made
fibers are used due to their good combination of physico-mechanical and thermal behaviour.

5.Particulate Composite
Particulate composite consists of the composite material in which the filler materials are roughly
round. An example of this type of composite would be the unreinforced concrete where the
cement is the matrix and the sand serves as the filler. Lead particles in copper matrix is another
example where both the matrix and the filler are metals. Cermet is a metal matrix with ceramic
filler. Particulate composites offer isotropic properties of composite along with increase in
toughness. Particulate composites are used with all three types of matrix materials metals,
polymers and ceramics.

6.Flake composites
Flakes are often used in place of fibers as can be densely packed. Metal flakes that are in close
contact with each other in polymer matrices can conduct electricity or heat, while mica flakes

and glass can resist both. Flakes are not expensive to produce and usually cost less than fibers.
But they fall short of expectations in aspects like control of size, shapeand show defects in the
end product. Glass flakes tend to have notches orcracks around the edges, which weaken the
final product. They are also resistant to be lined up parallel to each other in a matrix, causing
uneven strength.

Figure-1.1 Schematic diagram of different types of Composite

APPLICATIONS OF COMPOSITES
Composites are one of the most widely used materials because of their adaptability to different
situations and the relative ease of combination with other materials to serve specific purposes
and exhibit desirable properties.
In surface transportation, reinforced plastics are the kind of composites used because of their
huge size. They provide ample scope and receptiveness to design changes, materials and
processes. The strength-weight ratio is higher than other materials. Their stiffness and cost
effectiveness offered, apart from easy availability of raw materials, make them the obvious
choice for applications in surface transportation.
In heavy transport vehicles, the composites are used in processing of component parts with costeffectiveness. Good reproductivity and resilience handling by semi-skilled workers are the
basic requirements of a good composite material. While the costs of achieving advanced

composites may not justify the savings obtained in terms of weight vis-a-vis vehicle production,
carbon fibers reinforced epoxies have been used in racing cars and recently for the safety of cars.
Polyester resin with suitable fillers and reinforcements were the first applications of composites
in road transportation. The choice was dictated by properties like low cost, ease in designing and
production of functional parts etc. Using a variety of reinforcements, polyester has continued to
be used in improving the system and other applications.
Most of the thermoplastics are combined with reinforcing fibers in various proportions. Several
methods are used to produce vehicle parts from thermo plastics. Selection of the material is made
from the final nature of the component, the volume required, apart from cost-effectiveness and
mechanical strength.
Components that need conventional paint finishing are generally made with thermosetting resins,
while thermoplastics are used to build parts that are moulded and can be pigmented. Press
moulded reinforced polyester possess the capability to produce large parts in considerable
volume with cost-effectiveness.
In manufacturing of automobile parts, glass and sisal fibers usually find the maximum use. Sisal
costs very less and this alone has prompted extensive research to come up with applications in
which sisal is the dominant reinforcing material in filled polyester resin, in parts where specific
mechanical properties are required and appearance is not very important. Heater housings, which
find uses for sisal, are produced by compression moulding. Since a variety of glass fibers are
available, it is used as reinforcement for a large range of parts of different types. Rovings, nonwoven mats are the commonly used low cost versions. Woven cloth is applied in special cases,
where particular properties are required as cloth is not known to be amenable to large quantity
production methods.
A reinforced-plastic composite is likely to cost more than sheet steel, when considered on the
basis of cost and performance. In such a case, other qualities must necessarily justify the high
expenditure. Mechanical properties of the parts, which affect the thickness and weight, must
offer enough savings to render them more effective than steel. It however shows a higher
machining waste than reinforced plastics.