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COMPOSITE MATERIALS
Are a combination of two or more elements that create a material with different characteristics than
the elements that compose it.
They are commonly composed of a main mass referred to as a
matrix and strengthening agent that acts as a binder referred to as a
resin. Other materials can be applied to the matrix in order to provide
more stability in the composite. These layers create an envelope
around the matrix completely enclosing it and creating a much stronger material.
Composites fall within 3 categories:
Carbon Fiber
Carbon Nanotubes
Ceramic Composite
Carbon Fiber
Carbon Nanotubes
Ceramic Composite
RESINS
They provide strength and adhesion capabilities to a composite material. They can also act as the
matrix in a fiber reinforced material.
RESIN SYSTEMS
Polyesters
Advantages:
Easy to use
Lowest cost of resins
Available ($1.50-3/kg)
Disadvantages:
Only moderate mechanical
properties
High styrene emissions in
open moulds
High cure shrinkage Limited
range of working times
Vinylesters
Advantages:
Very high chemical/environmental resistance
Higher mechanical properties
than polyesters
Disadvantages:
Post cure generally required
for high properties High styrene content j
Higher cost than polyesters
($3-4.50/kg)
High cure shrinkage
Epoxies
Advantages:
High mechanical and thermal
properties
High water resistance
Long working times available
Temperature resistance can
be I to 140C wet / 220C
dry
Low cure shrinkage
Disadvantages:
Post cure generally required
for high properties
High styrene content j
Higher cost than polyesters
($3-4.50/kg)
High cure shrinkage
Disadvantages:
More expensive than vinylesters ($4.50-22.50/kg)
Critical mixing
Corrosive handling
ARAMID FIBER
CARBON FIBER
ARAMID FIBER
CARBON FIBER
Aramid fiber is a man-made organic polymer (an aromatic polyamide) produced by spinning a solid fiber from a liquid chemical
blend. The bright golden yellow filaments produced can have a
range of properties, but all have high strength and low density
giving very high specific strength. All grades have good resistance
to impact, and lower modulus grades are used extensively in ballistic applications. Compressive strength, however, is only similar to
that of E glass.
Carbon fiber is produced by the controlled oxidation, carbonization
and graphitisation of carbon-rich organic precursors which are
already in fiber form. The most common precursor is polyacrylonitrile (PAN), because it gives the best carbon fiber properties, but
fibers can also be made from pitch or cellulose. Variation of the
graphitisation process produces either high strength fibers (@
~2,600C) or high modulus fibers (@ ~3,000C) with other types
in between. Once formed, the carbon fiber has a surface treatment applied to improve matrix bonding and chemical sizing which
serves to protect it during handling.
CORE MATERIALS
Polyurethane foam
PVC foams are widely used core materials in the marine, surface transport, aerospace, and wind
energy industries due to their consistent density, high moisture resistance, and excellent physical properties.
CORE MATERIALS
Honeycomb cores
Paper core
Wood cores
Aluminum core
OTHER COMPOSITES
Large particles
Concrete
SMART APPLICATIONS
Using carbon ber reinforced
lament for 3D printing.
Thinner structures allow for
more opportunities to enable
the facade to accommodate
an array of systems.
Opportunity to create a
composite smart materials.
E.G. Carbon ber and
photovoltaic cells.
CARBON FIBER
Carbon fiber is produced by the controlled oxidation, carbonization and graphitisation of
carbon-rich organic precursors which are already in fiber form. The most common precursor is polyacrylonitrile (PAN), because it gives the best carbon fiber properties, but fibers
can also be made from pitch or cellulose. Variation of the graphitisation process produces
either high strength fibers (@ ~2,600C) or high modulus fibers (@ ~3,000C) with other
types in between. Once formed, the carbon fiber has a surface treatment applied to improve matrix bonding and chemical sizing which serves to protect it during handling.
TYPES OF FIBER
CONTINUOUS TOW
CHOPPED
MILLED
FABRIC
WOVEN FABRICS
FELT
CARBON FIBER
CHARACTERISTICS
CARBON FIBER
APPLICATIONS
https://youtu.be/hjErH4_1fks
Automotive
https://youtu.be/RiPQpiE4_qY
3D printing
CARBON FIBER
Grades
Carbon fiber is the result of heating polyacrylanitrile fiber to intense temperatures that remove
the majority of its elements except the carbon. This process is called pirolyzing process. The
resulting fiber after this process has the tensile modulus of 33 million pounds per square inch
(MSI), this is also referred as the standard modulus. By processing the strand even further this
will yield a higher tensile modulus equal to 42 MSI. This intermediate modulus creates smaller
strands than the standard allowing for more fibers to be packed in thus creating higher stiffness. The high modulus fiber are the result of heating the fibers even more. This results in a
tensile modulus of 55 MSI and fibers much more denser and smaller than the standard modulus which makes the fibers more brittle and fairly more expensive.
Fibers are sold in bundles designated by a (K) which signfies thousands of fibers. The most
common denominations are: 1K, 3K, 6K, 12K, 24K, 50K. These bundles are then used for
weaving fabrics that can be later be applied in numerous applciations.
RESOURCES
Addington, Michelle and Schodek,Daniel, "Smart Materials and New Technologies For Architecture and
Design Professions", Massachusetts: Architectural Press, 2005.
Buckley, John D., and Danny Dale Edie. Carbon-carbon materials and composites. Vol. 1254. William
Andrew, 1993.
http://calfeedesign.com/tech-papers/grades-of-carbon-fiber/
Lee, Henry, and Kris Neville. "Handbook of epoxy resins." (1967).
https://books.google.com/books?hl=en&lr=&id=BRcdDu4bUhMC&oi=fnd&pg=PR13&dq=composite
+materials&ots=E2D4izG16Y&sig=O4XOB46nsHz2o5F2vEbVJqY6q30#v=onepage&q=composite
%20materials&f=false
http://www.som.com/news/worlds_largest_3dprinted_polymer_building_will_be_shown_at_international_builders_show
http://zoltek.com/products/panex-35/