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Advantages
Applications
Types of Composites
Matrix
phase/Reinforc
ement Phase
Metal
Ceramic
Polymer
Metal
Powder metallurgy
parts combining
immiscible metals
Brake pads
Ceramic
SiC reinforced
Al2O3
Tool materials
Fiberglass
Kevlar fibers in an
epoxy matrix
Polymer
Elemental
(Carbon,
Boron, etc.)
Fiber reinforced
metals
Auto parts
aerospace
Rubber with
carbon (tires)
Boron, Carbon
reinforced plastics
MMCs
CMCs
PMCs
A. Fiber Composites
In fiber composites, the fibers reinforce along the line of
their length. Reinforcement may be mainly 1-D, 2-D or 3-D.
Figure shows the three basic types of fiber orientation.
1-D gives maximum strength in
one direction.
2-D gives strength in two
directions.
Isotropic gives strength equally
in all directions.
B. Particle Composites
Particles usually reinforce a composite equally in all directions
(called isotropic). Plastics, cermets and metals are examples of
particles.
Particles used to strengthen a matrix do not do so in the same
way as fibers. For one thing, particles are not directional like
fibers. Spread at random through out a matrix, particles tend to
reinforce in all directions equally.
Cermets
(1) OxideBased cermets
(e.g. Combination of Al2O3 with Cr)
(2) CarbideBased Cermets
(e.g. Tungstencarbide, titaniumcarbide)
Metalplastic particle composites
(e.g. Aluminum, iron & steel, copper particles)
Metalinmetal Particle Composites and
Dispersion Hardened Alloys
(e.g. Ceramicoxide particles)
C. Flake Composites - 1
Flakes, because of their shape, usually
reinforce in 2-D. Two common flake
materials are glass and mica. (Also
aluminum is used as metal flakes)
C. Flake Composites -2
A flake composite consists of thin, flat flakes
held together by a binder or placed in a
matrix. Almost all flake composite matrixes
are plastic resins. The most important flake
materials are:
1. Aluminum
2. Mica
3. Glass
C. Flake Composites -3
Basically, flakes will provide:
Uniform mechanical properties in the plane of
the flakes
Higher strength
Higher flexural modulus
Higher dielectric strength and heat resistance
Better resistance to penetration by liquids and
vapor
Lower cost
D. Laminar Composites - 1
Laminar composites involve two or more
layers of the same or different materials. The
layers can be arranged in different directions
to give strength where needed. Speedboat
hulls are among the very many products of
this kind.
D. Laminar Composites - 2
Like all composites laminar composites
aim at combining constituents to produce
properties that neither constituent alone
would have.
In laminar composites outer metal is not
called a matrix but a face. The inner
metal, even if stronger, is not called a
reinforcement. It is called a base.
D. Laminar Composites - 3
We can divide laminar composites into three basic types:
Unreinforcedlayer composites
(1) AllMetal
(a) Plated and coated metals (electrogalvanized
steel steel plated with zinc)
(b) Clad metals (aluminumclad, copperclad)
(c) Multilayer metal laminates (tungsten, beryllium)
(2) MetalNonmetal (metal with plastic, rubber, etc.)
(3) Nonmetal (glassplastic laminates, etc.)
Reinforcedlayer composites (laminae and laminates)
Combined composites (reinforcedplastic laminates
well bonded with steel, aluminum, copper, rubber,
gold, etc.)
D. Laminar Composites - 4
A lamina (laminae) is any
arrangement of unidirectional
or woven fibers in a matrix.
Usually this arrangement is
flat, although it may be
curved, as in a shell.
A laminate is a stack of
lamina arranged with their
main reinforcement in at least
two different directions.
E. Filled Composites
There are two types of filled composites. In
one, filler materials are added to a normal
composite result in strengthening the
composite and reducing weight. The second
type of filled composite consists of a skeletal
3-D matrix holding a second material. The
most widely used composites of this kind are
sandwich structures and honeycombs.
F. Combined Composites
It is possible to combine
several different materials
into a single composite. It is
also possible to combine
several different composites
into a single product. A good
example is a modern ski.
(combination of wood as
natural fiber, and layers as
laminar composites)
Particulate
Flakes
Fiber Reinforcement
The typical composite consists of a matrix holding
reinforcing materials. The reinforcing materials, the
most important is the fibers, supply the basic
strength of the composite. However, reinforcing
materials can contribute much more than strength.
They can conduct heat or resist chemical corrosion.
They can resist or conduct electricity. They may be
chosen for their stiffness (modulus of elasticity) or for
many other properties.
Types of Fibers
The fibers are divided into two main groups:
Glass fibers: There are many different kinds of glass,
ranging from ordinary bottle glass to high purity quartz
glass. All of these glasses can be made into fibers.
Each offers its own set of properties.
Advanced fibers: These materials offer high strength
and high stiffness at low weight. Boron, silicon, carbide
and graphite fibers are in this category. So are the
aramids, a group of plastic fibers of the polyamide
(nylon) family.
Fibers - Glass
Fiberglass properties vary somewhat according to the type of glass
used. However, glass in general has several wellknown
properties that contribute to its great usefulness as a reinforcing
agent:
Tensile strength
Chemical resistance
Moisture resistance
Thermal properties
Electrical properties
Aglass
Cglass
Eglass
Sglass
Fibers - Glass
Most widely used fiber
Uses: piping, tanks, boats, sporting goods
Advantages
Low cost
Corrosion resistance
Low cost relative to other composites:
Disadvantages
Types:
Examples
Advantages:
higher strength and lighter than glass
More ductile than carbon
Fibers - Carbon
2nd most widely used fiber
Examples
Advantages
Intermediate modulus
PAN (Polyacrylonitrile)
fiber precursor heated and stretched to align structure
High modulus
Fibers - Others
Boron
Textile industry
High strength
Extremely light weight
Low range of temperature usage
Fiber Strength
Matrix Materials
Functions of the matrix
Demands on matrix
Matrices - Polymeric
Thermosets
Epoxy resins
Matrices - Thermosets
Polyester
Polyesters have good mechanical properties, electrical
properties and chemical resistance. Polyesters are
amenable to multiple fabrication techniques and are low
cost.
Vinyl Esters
Vinyl Esters are similar to polyester in performance.
Vinyl esters have increased resistance to corrosive
environments as well as a high degree of moisture
resistance.
Matrices - Thermosets
Epoxy
Epoxies have improved strength and stiffness properties
over polyesters. Epoxies offer excellent corrosion
resistance and resistance to solvents and alkalis. Cure
cycles are usually longer than polyesters, however no
by-products are produced.
Flexibility and improved performance is also achieved
by the utilization of additives and fillers.
Matrices - Thermoplastics
Formed by heating to elevated temperature
at which softening occurs
Reversible reaction
Can be reformed and/or repaired - not common
Limited in temperature range to 150C
Examples
Polypropylene
with nylon or glass
can be injected-- inexpensive
Matrices - Others
Metal Matrix Composites - higher
temperature
Important Note
Composite properties are less than
that of the fiber because of dilution
by the matrix and the need to orient
fibers in different directions.
MANUFACTURING PROCESSES
OF COMPOSITES
Composite materials have succeeded remarkably in their
relatively short history. But for continued growth,
especially in structural uses, certain obstacles must be
overcome. A major one is the tendency of designers to
rely on traditional materials such as steel and aluminum
unless composites can be produced at lower cost.
Cost concerns have led to several changes in the
composites industry. There is a general movement
toward the use of less expensive fibers. For example,
graphite and aramid fibers have largely supplanted the
more costly boron in advancedfiber composites. As
important as savings on materials may be, the real key
to cutting composite costs lies in the area of processing.
Layup
Curing
Curing is the drying and hardening (or polymerization) of
the resin matrix of a finished composite. This may be
done unaided or by applying heat and/or pressure.
Layup basically is the process of arranging fiber
reinforced layers (laminae) in a laminate and shaping
the laminate to make the part desired. (The term layup
is also used to refer to the laminate itself before curing.)
Unless prepregs are used, layup includes the actual
creation of laminae by applying resins to fiber
reinforcements.
A. Winding Operation
The most important operation in this category is filament
winding. Fibers are passed through liquid resin, and then
wound onto a mandrel. After layup is completed, the
composite is cured on the mandrel. The mandrel is then
removed by melting, dissolving, breakingout or some
other method.
B. Molding Operations
Molding operations are used in making a large number of
common composite products. There are two types of
processes:
A. Openmold
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Hand layup
Sprayup
Vacuumbag molding
Pressurebag molding
Thermal expansion molding
Autoclave molding
Centrifugal casting
Continuous pultrusion and pulforming.
1. Hand Lay-up
Hand layup, or contact molding, is the oldest and
simplest way of making fiberglassresin composites.
Applications are standard wind turbine blades, boats,
etc.)
2. Spray-up
In Sprayup process, chopped fibers and resins are
sprayed simultaneously into or onto the mold. Applications
are lightly loaded structural panels, e.g. caravan bodies,
truck fairings, bathtubes, small boats, etc.
3. Vacuum-Bag Molding
The vacuumbag process was developed for making
a variety of components, including relatively large
parts with complex shapes. Applications are large
cruising boats, racecar components, etc.
4. Pressure-Bag Molding
Pressurebag process is virtually a mirror image of
vacuumbag molding. Applications are sonar domes,
antenna housings, aircraft fairings, etc.
6. Autoclave Molding
Autoclave molding is similar to both vacuumbag and
pressurebag molding. Applications are lighter, faster
and more agile fighter aircraft, motor sport vehicles.
7. Centrifugal Casting
Centrifugal Casting is used to form round objects such as
pipes.
pultrusion
composite
of metal
Complex
made.
B. Closedmold
(1) Matcheddie molding: As the name
suggests, a matcheddie mold consists
of closely matched male and female
dies (shown in figure). Applications are
spacecraft parts, toys, etc.
(2) Injection molding: The injection
process begins with a thermosetting
(or sometimes thermoplastic) material
outside the mold. The plastic may
contain reinforcements or not. It is first
softened by heating and/or mechanical
working with an extrusiontype screw.
It is then forced, under high pressure
from a ram or screw, into the cool
mold. Applications are auto parts,
vanes, engine cowling defrosters and
aircraft radomes.
assemble fibers
impregnate resin
shape product
cure resin
low manufacturing
costs if high
throughput
e.g., Glass fiber pipe,
sailboard masts
Prepregs
Prepreg and prepreg layup
wound on spools
Cut and stacked
Curing conditions
Typical temperature and pressure in autoclave
Manufacturing - Layups
compression
molding
vacuum bagging
Material Forms
Textile forms
Braiding or weaving
Tubular braided form
Fabric Structures
Woven:
Knit:
Braided:
Woven Fabrics
Basic woven fabrics consists of two
systems of yarns interlaced at right
angles to create a single layer with
isotropic or biaxial properties.
Physical Properties
Construction (ends & picks)
Weight
Thickness
Weave Type
Braiding
A braid consists of two sets of yarns, which are helically
intertwined.
The resulting structure is oriented to the longitudinal axis
of the braid.
This structure is imparted with a high level of
conformability, relative low cost and ease of manufacture.
Braid Structure
Types of Braids
Triaxial Yarns
A system of longitudinal yarns can be introduced
which are held in place by the braiding yarns
These yarns will add dimensional stability, improve
tensile properties, stiffness and compressive strength.
Yarns can also be added to the core of the braid to
form a solid braid.
Material Forms
Pultrusion
Fiber and matrix are pulled through a
die, like extrusion of metals -assembles fibers, impregnates the
resin, shapes the product, and cures
the resin in one step.
Example. Fishing rods
Pultrusion
Manufacturing
Tube rolling - tubular products
Examples
fishing rods
golf clubs
oars