Composites Science and Technology 63 (2003) 20292044

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Articial neural networks applied to polymer composites: a review

Z. Zhang*, K. Friedrich
Institute for Composite Materials (IVW GmbH), University of Kaiserslautern, Erwin Schroedinger Str. 58, 67663 Kaiserslautern, Germany

Received 16 October 2002; received in revised form 31 January 2003; accepted 7 March 2003

Abstract
Inspired by the biological nervous system, an articial neural network (ANN) approach is a fascinating mathematical tool, which
can be used to simulate a wide variety of complex scientic and engineering problems. A powerful ANN function is determined
largely by the interconnections between articial neurons, similar to those occurring in their natural counterparts of biological
systems. Also in polymer composites, a certain amount of experimental results is required to train a well-designed neural network.
After the network has learned to solve the material problems, new data from the similar domain can then be predicted without
performing too many, long experiments. The objective of using ANNs is also to apply this tool for systematic parameter studies in
the optimum design of composite materials for specic applications. In the present review, various principles of the neural network
approach for predicting certain properties of polymer composite materials are discussed. These include fatigue life, wear perfor-
mance, response under combined loading situations, and dynamic mechanical properties. Additionally, the ANN approach has
been applied to composite processing optimizations. The goal of this review is to promote more consideration of using ANNs in the
eld of polymer composite property prediction and design.
# 2003 Elsevier Ltd. All rights reserved.
Keywords: Review; A. Polymers; Composites; Articial neural networks (ANNs); Design; Processing; Properties

1. Introduction resistant polymer composites [2]. First, the matrix

Nowadays, the application of polymer composites as
engineering materials has become state of the art. To
design the characteristics of polymer composites is the
most important advantage. In order to meet a special
target of engineering application, e.g. concerning one or
several measurable material properties, polymer com-
posites can be designed by selecting the correct compo-
sition and choosing the appropriate manufacturing
process, as schematically illustrated in Fig. 1. There are
many possibilities to create polymer composites con-
taining dierent llers and/or reinforcements (Fig. 2)
[1]. In addition, not only dierent kinds but also various
properties of matrix material and llers/reinforcements,
as well as the ber orientations and, in case of con-
tinuous ber composites, the laminate parameters can
be considered. As a special example, Fig. 3 illustrates
the general principles for the systematic design of wear
* Corresponding author. Tel.: +49-631-201-7213; fax: +49-631-
201-7196.
E-mail address: zhang@ivw.uni-kl.de (Z. Zhang).
0266-3538/03/$ - see front matter # 2003 Elsevier Ltd. All rights reserved.
doi:10.1016/S0266-3538(03)00106-4
should have high temperature resistance and high cohe-
sive strength. To reduce the adhesion and the frictional
coecient, internal lubricants such as polytetra-
uoroethylene and graphite akes are frequently incor-
porated. Short aramid, glass or carbon bers are used to
increase the creep resistance, the hardness and the com-
pressive strength of the polymer matrix, and additional
llers that enhance the thermal conductivity are also of
great advantage.
In the manufacturing process, some key parameters,
e.g. curing temperatures and manufacturing speed,
which govern the nal quality of the composites, should
be also analyzed. Property investigation plays a key role
in materials science to evaluate composites designed for
special engineering applications. All three stages shown
in Fig. 1 are not separated, but interconnected, and the
integration can be summarized as composite design,
processing optimization and property relationships (as
indicated additionally in Fig. 1). The rst two elds
correspond to the interaction between the selected com-
positions or the manufacturing process and the proper-
ties investigated, whereas the last relates to possible
2030 Z. Zhang, K. Friedrich / Composites Science and Technology 63 (2003) 20292044

correlations between some simple measured parameters
(e.g. modulus, strength and failure strain) and more
complex properties (e.g. fatigue, wear, combined load-
ing and creep). The understanding of all these relation-
ships is important in composite materials science, in
order to meet the requirements for particular engineer-
ing applications.
Modeling of these relationships generally involves the
development of a mathematical tool derived from
experimental data; once established it can signicantly
reduce the experimental work involved in designing new
polymer composites. For this reason, articial neural
networks (ANNs) have recently been introduced into the
eld of polymer composites. Inspired by the biological

Fig. 1. Schematic presentation of composition selection, manufacturing process, and property investigation in composite materials science.

Fig. 2. Systematic illustration of the structural components of composite materials [1].

Fig. 3. Schematic presentation how to design the composition of wear resistant polymer composites [2].
 Z. Zhang, K. Friedrich / Composites Science and Technology 63 (2003) 20292044
nervous system, ANNs can be used to solve a wide
variety of complex scientic and engineering problems.
Like their biological counterparts, ANNs can learn
from examples, and therefore can be trained to nd
solutions of the complex non-linear, multi-dimensional
functional relationships without any prior assumptions
about their nature; further, the network is built directly
from experimental data by its self-organizing cap-
abilities. Although there are not many publications
about the use of ANNs in the polymer composite eld
up to now, the available literature at least covers var-
ious topics, from fatigue prediction to wear simulation,
and from monitoring of the manufacturing process to
analysis of composite curing. It shows that the ANNs
approach can be properly employed in all the simula-
tions of the interactions illustrated in Fig. 1. It is,
therefore, very valuable to summarize and recapitulate
the developments and applications of ANNs, which is
the intention of the present review, in order to promote
wider consideration of the use of this potential
mathematical tool in polymer composites research.
2. Articial neural networks
2.1. What are articial neural networks?
Articial neural networks are computational systems
that simulate the microstructure (neurons) of a biologi-
cal nervous system. The most basic components of
ANNs are modeled after the structure of the brain, and
therefore even the terminology is borrowed from neu-
roscience. It is necessary to give a fundamental descrip-
tion of natural nerve system in this paragraph that is
available in many textbooks [37]. The most basic ele-
ment of the human brain is a specic type of cell, which
provides us with the abilities to remember, think, and
apply previous experiences to our every action. These
cells are known as neurons, and each of these neurons
can connect with up to 200,000 other neurons. The
power of the brain comes from the numbers of these
basic components and the multiple connections between
them. All natural neurons have four basic components,
which are dendrites, soma, axons, and synapses. Basi-
cally, a biological neuron receives input from other
sources, combines them in some way, performs a gen-
erally nonlinear operation on the result, and then out-
puts the nal result. Biological neural networks are
constructed in a three-dimensional way from microscopic
components. These biological neurons seem capable of
almost unlimited interconnections.
Inspired by biological neurons, ANNs are composed
of simple elements operating in parallel, i.e. ANNs are
the simple clustering of the primitive articial neurons.
This clustering occurs by creating layers, which are then
connected to one another. How these layers connect
2031
may also vary. Basically, all ANNs have a similar
topological structure. Some of the neurons interface
with the real world to receive its input, and other neu-
rons provide the real world with the networks output.
All the rest of the neurons are hidden from view. As in
nature, the network function is determined largely by
the interconnections between neurons, which are not
simple connections, but some non-linear functions.
Each input to a neuron has a weight factor of the func-
tion that determines the strength of the interconnection
and thus the contribution of that interconnection to the
following neurons. ANNs can be trained to perform a
particular function by adjusting the values of these
weight factors between the neurons, either from the
information from outside the network or by the neurons
themselves in response to the input. This is the key to
the ability of ANNs to achieve learning and memory.
For this reason, ANNs were dened by Aleksander
and Morton [3] as a massively parallel-distributed pro-
cessor made up of simple processing units, which has a
natural propensity for storing experiential knowledge
and making it available for use. It resembles the brain in
two respects:
1. Knowledge is acquired by the network from its
environment through a learning process.
2. Inter-neuron connection strengths, known as
synaptic weights, are used to store the acquired
knowledge.
2.2. Training process of backpropagation ANNs
The multi-layered neural network is the most widely
applied neural network, which has been utilized in most
of the research reviewed in this paper. A back-
propagation algorithm can be used to train these multi-
layer feed-forward networks with dierentiable transfer
functions to perform function approximation, pattern
association, and pattern classication. The term back-
propagation refers to the process by which derivatives
of network error, with respect to network weights and
biases, can be computed. The training of ANNs by
backpropagation involves three stages [4]: (i) the feed-
forward of the input training pattern, (ii) the calculation
and backpropagation of the associated error, and (iii)
the adjustment of the weights. This process can be used
with a number of dierent optimization strategies.
Fig. 4 illustrates schematically a multi-layer feed-for-
ward ANN conguration in its upper part. It can be
seen that ANNs are conventionally constructed with
three layers, i.e. input, output and hidden layers. Hid-
den layers can contain one or several layers for its
practical application. Each layer has dierent numbers
of neural elements. As in nature, the network function is
largely determined by the connections between these
elements. When we focus on one neural element, as
2032 Z. Zhang, K. Friedrich / Composites Science and Technology 63 (2003) 20292044
schematically drawn in the lower part of Fig. 4, the
relationship between the input vector Xin and output
vector Xjn1 of this element can be described as follows:
!
n1
X n n
Xj F Wji Xi 1 The total sum squared error E is averaged over all
i patterns in the training set, in which dp is the target
1 actual output (measured). In the minimization process,
where F(x) is the tan-sigmoid function Fx
1 ex
or other nonlinear transfer function, e.g. log-sigmoid
function, and Xjn1 is output of unit j in the nth layer,
Wjin is a weight from unit i in nth layer to unit j in
(n+1)th layer. An input vector is presented to the units
of the input layer. Units in the next layer compute a
weighted sum of the input, and output the result of a
nonlinear function to the sum. The learning procedure
is based on a gradient search, with a least sum squared
optimality criterion of errors between the predicted and
desired values:
Fig. 4. Articial neural network conguration (upper part). The lower
part gives a schematic description of the relationship between the
input and output vectors of one neuron.
X
P  2
E dp  op 2
p1
output (predicted) for the pth pattern and op is the
the weights of all the connecting nodes are adjusted
until the desired error level is achieved or the maximum
number of cycles is reached. The learning algorithm
used here for the weights is
Wjin t 1 Wjin t DWjin t 3
with its correction
@E
DWjin t 1 
DWjin t; 4
@Wjin
where Wjin t is the training signal of the correct answer
at the tth learning step, DWjin t is the correction of the
weight at the tth learning step,
is the learning rate, and
 is the momentum factor.
is a small parameter to
adjust the correction each time, and  reduces an oscil-
lation and aids rapid convergence. Appropriate values
of these parameters aid network learning.
To avoid limiting the output to a small range, a linear
transfer function is employed between the hidden and
the output layer. It is believed that the two-layer sig-
moid/linear network can represent any functional rela-
tionship between input and output if the sigmoid layer
has enough neurons. Details about the theory and
mathematics behind the neural networks can be found
additionally in several textbooks [37].
The most suitable applications for ANNs have the
following characteristics [8]:
1. A large database is available.
2. It is dicult to nd an accurate solution to the
problem by existing mathematical approaches.
3. The dataset is incomplete, noisy or complex.
Some properties of polymer composites, i.e. fatigue,
wear, and creep, have all of these characteristics and are
therefore example material behavior that are suitable
for neural network analysis.
2.3. Over-tting problem [9]
Multi-layer feed-forward neural networks are believed
to be able to represent any functional relationship
between input and output if there are enough neurons in
the hidden layers. However, too many neurons in the
hidden layers may cause another problem, so called
over-tting. The error on the training set is driven to a
very small value due to the powerful ANN learning
process, but when new data is presented to the network
the error is large. The network has memorized the
 Z. Zhang, K. Friedrich / Composites Science and Technology 63 (2003) 20292044
training examples, but it has not learned to generalize to
new situations. Clearly when over-tting occurs, the
network will not generalize well. The ideal method for
improving network generalization is to use a network
that is just large enough to provide an adequate t. The
larger a network is, the more complex are the functions
the network can create. Therefore, if we use a small
enough network, it will not have enough power to over-
t the data. Unfortunately, it is dicult to know
beforehand how large a network should be for a specic
application. There are two methods for improving gen-
eralization: regularization and early stopping. The
method of regularization, like Bayesian regularization,
involves modifying the performance function, which is
normally chosen to be the sum of squares of the net-
work errors on the training set. In Bayesian regulariza-
tion, the weights and biases of the network are assumed
to be random variables with specied distributions. The
regularization parameters are related to the unknown
variances associated with these distributions, and these
parameters can be estimated using statistical techniques.
Early stopping concerns a third group of dataset (a
validation dataset besides the training dataset and test
dataset), which is used to monitor the training process.
When the validation error increases for a specied
number of iterations due to over-tting, the training is
stopped early, and the weights and biases are returned
to the minimum of the validation error.
2.4. Application of ANNs in composite materials science
For materials research, a certain amount of experi-
mental results is always needed rst to develop a well-
performing neural network, including its architecture,
training functions, training algorithms and other para-
meters, followed by the training process and evaluation
method. After the network has learned to solve the
problems based on these datasets, new data from the
same knowledge domain can then be put into the
trained neural network, in order to output realistic
solutions. The process of creating ANNs for materials
research can, therefore, be summarized in terms of the
following stages:
1. Database collection: analysis and pre-processing
of the data.
2. Training of the neural network: this includes the
choice of its architecture, training functions,
training algorithms and parameters of the net-
work.
3. Test of the trained network: to evaluate the net-
work performance.
4. Use of the trained ANNs for simulation and pre-
diction.
The greatest advantage of ANNs is its ability to
model complex non-linear, multi-dimensional functional
2033
relationships without any prior assumptions about the
nature of the relationships, and the network is built
directly from experimental data by its self-organizing
capabilities. However, the limitations of the ANN
method are as follows:
1. Training data of the database should have a close
relationship with the predicting parameters.
2. Sucient training data for complex ANNs are
necessary.
3. ANNs are purely phenomenological and does not
inherently produce a mechanistic understanding of
the process being modeled. Nevertheless, well-
trained ANNs may contribute to the development
of a mechanistic understanding of the problem
considered.
2.5. Evaluation of the ANN method
A dataset of measurement results will usually be divi-
ded into a training dataset and a test dataset. The
training dataset is used to adjust the weights of all the
connecting nodes until the desired error level is reached.
Thereafter, the network performance is evaluated by
using the test dataset. The quality of the prediction can
normally be characterized by the root mean square
error (RMSE) of the predicted values from the real
measured data. The smaller the RMSE of the test data-
set is, the higher is the predictive quality.
As an improvement, the coecient of determination B
(also called R2 coecient in some publications) has been
introduced to evaluate ANNs quality, dened by
M 
P  2
O pi  O i
B 1  i1 M 5
P 2
O i  O
i1
where O(p(i)) is the ith predicted property characteristic,
O(i) is the ith measured value, O is the mean value of
O(i), and M is the number of test data. The coecient B
describes the t of the ANNs output variable approx-
imation curve to the actual test data output variable
curve. Higher B coecients indicate an ANN with bet-
ter output approximation capabilities.
To avoid any articial inuence in selecting the test
data, a random technique can be applied in the selec-
tion, and the entire process is repeated independently
for many times (e.g. 50 times). Afterwards the distribu-
tion of B values is recorded and the percentage of
B50.9 is calculated, since this value is identied as a
high predictive quality, i.e. less than 15% of the RMSE
is between the predicted values and the measured ones.
It is clear that the higher the percentage of B50.9 is, the
better is the quality.
2034 Z. Zhang, K. Friedrich / Composites Science and Technology 63 (2003) 20292044
2.6. ANN conguration
Since the ANN1 conguration has a great inuence
on the predictive quality, various arrangements have
been considered in previous work. It is necessary to
dene a simple code to describe the ANN conguration,
as follows:
Nin  Nh1  Nh2  Nh3 e Nout 6 slightly higher than 90%. It seems that the ber orien-
where Nin and Nout are the element numbers of input
and output parameters, respectively, and e is the num-
ber of hidden layers. Nh1, Nh2 and Nh3 are numbers of
neurons in each hidden layer, respectively. For example,
7-[21]1-1 means a one hidden layer ANN with seven
input and one output parameters, with the hidden layer
containing 21 elements (neurons); 9-[15-10-5]3-1
denotes a nine input and one output ANN, with 15, 10
and ve neurons, respectively, in three hidden layers.
3. Articial neural networks for polymer composites
3.1. Fatigue life
Fatigue is one of the most complicated problems for
ber composites, and failure mechanisms are still not
well understood. Extensive tests must be carried out
because of the absence of a well-dened failure criterion
that can be used to predict fatigue failure in polymer
composites. ANNs oer the possibility of developing
models that will predict the behavior of composites
without being linked to mechanistic arguments. They
have, therefore, been introduced recently to predict the
fatigue life by Lee et al. [8], Aymerich and Serra [10],
and Al-Assaf and Kadi [11,12].
3.1.1. Unidirectional (UD) composites
Al-Assaf and Kadi [11] applied the ANN approach to
predict the fatigue life of UD glass ber/epoxy compo-
sites. UD ber composite specimens were prepared with
angle orientations of 0, 19, 45, 71, and 90 , and they
cyclically tested under load control condition with R-
ratios of 0.5, 0 and 1. Only the R-value, the maximum
stress and the ber orientation angle were used as the
1
ANN Software: The following ANN software are examples, which
have been used as the basis for polymer composite predictions, in which
the networks can be congured in a very wide variety of architectures,
and the training algorithms can be also dened exibly.
1. MATLAB Neural Networks Toolbox of MathWorks (http://
www.mathworks.com/).
2. NeuFrame of NeuSciences (http://www.neusciences.com/).
3. (http://www.aasdt.com/).
4. Neuralyst of Cheshire Engineering Corporation (http://
www.cheshireeng.com/).
5. Neurosolutions of NeuroDimension Inc. (http://www.nd.com/).
ANN input, and the output was the number of cycles to
fatigue failure. The database contained 92 measured
results. A 3-[12]1-1 ANN architecture was applied
which showed a very satisfactory predictive quality, in
which the RMSE was less than 20%. The corresponding
correlation coecient, probably similar to the B-value
dened in the previous section, corresponded to a value
tation in UD composites plays a key role in fatigue
performance. Applying ber orientation as an input
improves the ANN predictive quality signicantly, even
with a relatively smaller dataset of 92, compared with
the 400 mentioned in Ref. [8] for the laminates tested. In
order to improve the prediction accuracy, other types of
ANNs, i.e. modular, self-organizing, redial basis, and
principal component analysis networks, were considered
in a later publication [12] using the same database
employed in Ref. [11]. It is a pity that, based on the
successfully trained ANNs, the authors did not give any
further predictive results for the fatigue of other ber
orientations, since these were not measured in their
studies. In this way they missed the major advantage of
the neural networks approach in composite design, that
well-trained ANNs can predict the output properties of
new materials before manufacturing/testing the real
composites.
3.1.2. Laminate composites
Lee et al. [8] carried out an ANN prediction on the
fatigue life of some carbon/glass ber reinforced plastic
(CFRP/GFRP) laminates. As the rst step, an extensive
existing database of fatigue lives for four common
CFRPs, i.e. HTA/913, T800/5245, T800/924 and IM7/
977, all with [(45,02)2]S lay-up, was used to evaluate
possible ANN architectures and to develop training
methods for the network selected for detailed study. The
database contained more than 400 fatigue results over a
range of ve R-ratios of 1.5, 1.0, 0.3, +0.1, and
+10. Three fatigue parameters, peak stress, minimum
stress and probability of failure, and four monotonic
mechanical properties, tensile strength, compression
strength, tensile failure strain and tensile modulus, were
selected as the ANN inputs, which were applied to predict
the fatigue life of the composites as the output. A 7-[21]1-1
architecture ANN was nally optimized by evaluating the
changes in RMSE of network output with the number of
neurons in the hidden layer. Further eort was carried out
to reduce the size of the training dataset, and satisfactory
prediction was achieved. It was their conclusion that the
ANNs (a) can be trained at least to model constant-stress
fatigue behavior as well as other current life-prediction
methods, and (b) can provide accurate representations of
the stress/R-ratio/median-life surfaces for carbon ber
composites from a quite small experimental dataset.
Unfortunately, from their results the predictive ability for
minimum-life was less satisfactory and non-conservative.
 Z. Zhang, K. Friedrich / Composites Science and Technology 63 (2003) 20292044
Once a well-trained ANN was obtained, the possibi-
lity for predicting fatigue life of new materials could be
analyzed. As the second step of this paper, samples of
two other materials, a fth CFRP (HTA/982) laminate
and a GFRP (E-glass/913) laminate of similar structure,
were tested with regard to their mechanical and fatigue
properties. Monotonic mechanical properties of these
new materials were used as the input data to the well-
trained ANNs for predicting fatigue life, and the pre-
dictive results were compared with the related experi-
mental data. Both cases were unsatisfactory; the average
RMSE were of the order of 100% for the CFRP and
170% for the GFRP. It is clear that the use of CFRF
fatigue-life data to predict the fatigue-lives of GFRP
materials, or vice versa, is not recommended because of
the dierences in the mechanical and fatigue properties
of CFRP and GFRP. This example demonstrates that
even a well-trained ANN can only be used to predict
new data from the same knowledge domain.
As a pioneering example of fatigue prediction of
polymer composites using ANNs, this paper gives a
typical example for the property relationships shown in
Fig. 1. The authors tried to establish the relationships
between some relatively simple composite properties,
monotonic mechanical properties, with a complex
property, the fatigue life. Because the monotonic prop-
erties are easier to obtain than the fatigue data, suc-
cessful prediction could be of benet in reducing the
number of fatigue experiments. It is the reviewers opi-
nion that some key parameters, which may signicantly
inuence the fatigue behavior of composite laminates,
were missing in the selected ANN input. From the
reviewers experiences, it might have been helpful to add
some properties of the bers and the neat epoxy matrix,
e.g. the tensile strength of the bers, and the fracture
toughness as well as some fatigue data for the matrix, in
order to improve the predictive quality. The structure of
the lay-ups may also strongly aect the life of laminates,
which was also recognized by the authors.
The ANN predictive results of Aymerich and Serra
[10] conrmed that the properties of the basic elements
(lamina) and their orientation within the laminate
strongly aect the fatigue performance of composite
laminates. Therefore, the stacking sequence of the lami-
nate (e.g. a sequence [22.5/22.5/67.5/67.5]2S can be
described by the parameters of [22.5, 67.5], while a sin-
gle parameter of [45] identies the laminate [+45/
45]4S) was considered as the ANN input variable,
together with the number of cycles to failure, in order to
predict the fatigue strength as the ANN output para-
meter. four to twelve neurons were used in one hidden
layer, and the backpropagation algorithm was applied.
It was concluded that an ANN is a very attractive
approach to predict fatigue life of laminate composites,
although a larger dataset is needed when increasing the
number of laminate parameters.
2035
3.1.3. Brief comments
To conclude, some successes have been achieved using
ANN in the prediction of fatigue life of polymer com-
posites. However, the fatigue behavior is still so com-
plicated that the problem requires more eort before the
ANN can be used with more condence. Other pub-
lications on fatigue prediction in various metallic alloys
using the ANN approach [1315] are recommended to
the composite community as further references to
improve this technique for their problems.
3.2. Tribological properties
3.2.1. Wear of composites
Velten et al. [16] were among the earliest pioneers to
explore this approach in polymer composites, using
ANNs to predict the wear volume of short-ber/particle
reinforced thermoplastics. A total dataset of 72 inde-
pendent wear measurements was used to train and test
the neural network. The dataset came from fretting tests
with various material compositions (polyamide 4.6
matrix composites reinforced with short carbon/glass
bers, PTFE, and/or graphite) under dierent wear
measuring conditions. A 10-[25]1-1 structured ANN
was applied with the output of wear volume; the inputs
were mechanical properties and test conditions, i.e.
compressive strength, compression modulus, compres-
sive strain to failure, tensile strength, tensile strain to
failure, impact strength, environmental testing tem-
perature, initial load, average load and average velocity.
An automated Bayesian regularization of a back-
propagation algorithm was selected, which has the cap-
ability of automatically identifying the optimal size of
the articial neural network in its hidden layers. The
design and the training of the neural network were per-
formed using the Neural Network Toolbox of
MATLAB [9]. A randomly chosen test dataset was used
in the quality evaluation. Some successes were achieved
in this rst attempt at property analysis using ANNs to
deal with wear of polymer composites, even though the
predictive quality needed to be improved.
In further work, Zhang et al. [17] carried out
improvements based on an enlarged dataset of 103
independent measurements. The database contained (1)
the material compositions (volume fractions of the
matrix, the short glass bers, the pitch based carbon
bers, the PAN carbon bers, and the PTFE and Gra-
phite llers), (2) mechanical properties of the compo-
sites studied (compression modulus and strength,
impact strength, etc., all at relevant testing tempera-
tures), and (3) testing conditions (temperature, normal
force and sliding speed) as the input parameters; the
wear characteristics such as specic wear rate or fric-
tional coecient were chosen as the output data.
Firstly, the inuence of the dierent groups of input
parameters was analyzed. Table 1 gives the input and
2036 Z. Zhang, K. Friedrich / Composites Science and Technology 63 (2003) 20292044
output parameters in dierent cases, for which the
results of predictive qualities are analyzed in Fig. 5 [18].
In all these cases, 88 data were used for training and the
remaining 15 for testing. Again, the Bayesian algorithm
was applied. It can be seen that the addition of the
matrix volume as an input in the case of No. 2 eec-
tively improves the quality compared to that of No. 1,
in which only the mechanical properties were incorpo-
rated. The further use of all the ller contents in No. 3
reached a maximum percentage of 50% B higher than
0.9. In fact, even when using only the material compo-
sitions, without any mechanical properties, as an input
in the case No. 4, the ANN still obtained a good pre-
dictive quality of 38% test data with B50.9. The ANN
conguration used here was of the form 9-[25]1-1, i.e. it
possessed six material compositions and three measur-
ing conditions as the input, and the specic wear rate as
the output. It turned out that this was an ideal situation
for composite design (due to the well-trained ANN
used), since it allowed a property prediction to be made
by computer without manufacturing the real compo-
sites. This approver is, of course, only valid for the same
knowledge domain as the training dataset.
There are many variations of the backpropagation
algorithm due to the dierent methods for the gradient
descent algorithm. The following training algorithms [9]
were investigated, including Bayesian regularization
(BR), PowellBeale conjugate gradient algorithm
(CGB), BFGS quasi-Newton method (BFG), Adaptive
learning rate (GDX), and Levenberg-Marquardt algo-
rithm (LM). The results showed that both the BR and
CGB algorithms led to a high predictive quality, i.e.
nearly 40% of B were found to be 50.9 for the related
ANN conguration. Moreover, the BR is a better algo-
rithm to determine the optimal regularization para-
meters in an automated fashion. However, this
advantage is combined with a slow computing speed.
CGB is, on the other hand, a fast and high training
quality algorithm for this case. Both algorithms were
therefore considered in further work.
Not only the training algorithm but also the con-
guration has a strong inuence on the ANN predictive
quality. Based on the CGB algorithm, various ANN
congurations were analyzed, and the results were
Table 1
Input and output parameters for articial neural network predictions [18]
Number of cases
Vol.% of matrix (PA4.6)
Vol.% of llers (GF, pan CF, pitch CF, PTFE, and graphite)
Compressive properties (modulus, failure stress and failure strain)
Tensile properties (complex modulus, tension strength and failure strain)
Impact strength
Test conditions (testing temperature, normal force and sliding speed)
Specic wear rate
compared. The 9-[15-10-5]3-1 exhibited an excellent
result, showing that 66% of the test data had a B coef-
cient in the range from 0.9 to 1.0. However, from the
complexity of the conguration it also becomes clear
that the wear performance of short ber composites has
a very complex relationship with the input parameters
chosen. The number of training data denitely inu-
ences the predictive quality as well. When the number of
training data was reduced from 88 to 43 using the same
training algorithm of CGB and the same ANN con-
guration of 9-[15-10-5]3-1, the predictive qualities
were signicantly decreased. The dependence is shown
in Fig. 6 for the percentage of test data with a B-value
50.9 as a function of the number of training data. The
results were tted by the dashed line, and it becomes
clear that the larger the training dataset, the better is the
predictive quality.
The predictive quality was clearly improved when
compared to that of Ref. [16]. In that case, the material
compositions were not used as a part of the input data.
The increase in the number of data, 103 [17] instead of
72 [16], also contributed to this improvement. The cur-
rent situation shows that the predictive results exhibit
an excellent match to the real measured data. Figs. 7
and 8 exhibit in the form of a 3-D plot the predictive
results for the specic wear rate and frictional coecient
Fig. 5. Dependence of the percentage of test data B50.9 on the vari-
ous ANN input and output data described in Table 1 [18].
1 2 3 4
Input Input Input
Input Input
Input Input Input
Input Input Input
Input Input Input
Input Input Input Input
Output Output Output Output
 Z. Zhang, K. Friedrich / Composites Science and Technology 63 (2003) 20292044
as a function of PTFE- and pitch CF- vol.%, when
using six material compositions and three measuring
conditions as input parameters. Compared with the real
test results (dots with error bars in Figs. 7 and 8), the
predictive results are very acceptable. Therefore, once a
well-trained ANN has been obtained, new data can be
predicted without performing too many, long-duration
experiments, so that an ANN can signicantly reduce
the time required to design new polymer composites for
special purposes. It is clear that the predictive quality
could be further improved by enlarging the training
datasets, employing material compositions as input
data, and optimizing the ANN conguration.
Fig. 6. Dependence of the percentage of test data with a B-value in the
range of 0.91.0 on the number of training data. The dotted line is a
tted curve, which estimates that the more the training dataset is, the
better is the predictive quality [17].
Fig. 7. Specic wear rate of a polyamide 4.6 (PA4.6) composite as a
function of PTFE- and short CF-volume content. The experimental
data points and their scatters are given by the black bars, whereas the
rest of the 3-D plane was calculated by an articial neural network
approach (fretting test conguration, measuring conditions: testing
temperature T=20  C; normal force F=10 N; sliding speed v=0.04
m/s) [17].
2037
3.2.2. Erosive wear of polymers
Recently, Zhang et al. [19] applied this approach to
deal with the erosive wear data for three polymers, i.e.
polyethylene (PE), polyurethane (PUR), and an epoxy
modied by hygrothermally decomposed polyurethane
(EP-PUR). The impact angle for solid particle erosion
and some characteristic properties (material composi-
tions for the case of EP-PUR as well) were selected as
ANN input variables for predicting the erosive wear
rate. It seems that the ranking of the importance of
Fig. 8. Frictional coecient of a polyamide 4.6 (PA4.6) composite as
a function of PTFE- and short CF-volume content. The experimental
data points and their scatters are given by the black bars, whereas the
rest of the 3-D plane was calculated by an articial neural network
approach (fretting test conguration, measuring conditions: testing
temperature T=20  C; normal force F=10 N; sliding speed v=0.04
m/s) [17].
Table 2
Ranking of importance of input variables to erosive wear of epoxy
modied by hygrothermally decomposed polyurethane (EP-PUR)
predicted by ANNa [19]
Ranking Input variables Percentage of
B50.9 (%)
1 PUR content (wt.%) 84
1 Epoxy content (wt.%) 82
3 Density (g/cm3) 77
4 Mean molecular mass 72
between crosslinks (g/mol)
4 Fracture energy (kJ/m2) 72
4 Rubbery plateau onset temperature ( C) 72
7 Glass transition temperature ( C) 60
8 Rubbery plateau modulus (MPa) 28
9 Crosslink density ( 1020/cm3) 22
a
Erosive conditions, i.e. impact angle, mass ow rate, and velocity
of erodents, as well as one of the input variables in this table were
applied as ANN input to predict the erosive wear rate using a 4-[25]-1
structured neural network, which contains 25 neurons in its hidden
layer. The coecient of determination was calculated according to Eq.
(5), and the percentage of B50.9 was applied for ranking.
2038 Z. Zhang, K. Friedrich / Composites Science and Technology 63 (2003) 20292044
characteristic properties to the erosive wear rate could
oer some information about which property has a
stronger relationship to the wear of polymers. As an
example, for the EP-PUR polymer system, the weight
amount of PUR varied from 0, 20, 40, 60 to 80%. The
characteristic properties considered include density,
mean molecular mass between crosslinks, glass transi-
tion temperature (Tg), rubbery plateau modulus and
onset temperature, crosslink density, and fracture
energy. Four erosive impact angles, 30, 45, 60, and 90 ,
were used, and four types of erodents at various mass
ow rates and velocities were employed. Therefore, the
whole dataset for EP-PUR contained 80 independent
groups of data. The test duration was 60 s for all the
erosion measurements.
In order to investigate the correlations between ero-
sive wear rate and characteristic properties of these
polymers, each characteristic property was used only
with the necessary erosion conditions as input variables
for training the ANN. The qualities were analyzed by
the percentage of B50.9, which were used to rank the
importance of these characteristic properties to erosive
wear, as summarized in Table 2. It is clear that the
material compositions, i.e. epoxy and PUR weight con-
tent, show the strongest correlation with the wear per-
formance. This is in agreement with similar eects
found by Zhang et al. [17] for the ANN prediction of
the tribological properties of short ber reinforced
polymer composites. Density has the second more
important position due to its strong relationship to
composition. Mean molecular mass between crosslinks
(Mc) and fracture energy (Gc) exhibit a similar quality,
which may be explained by the dependence of Gc on M1/2
c .
The combined eect of density and Mc may reduce the
Fig. 9. Erosive wear rate of an epoxy modied by hygrothermally
decomposed polyurethane (EP-PUR) as a function of epoxy weight
content and impact angle of solid particle. Dots are experimental data,
whereas the rest of the 3-D plane was calculated by an articial neural
network approach (erodent: corundum, size=60
120 mm, mass ow for training the ANNs, and no fresh data were left for
rate=0.015 kg/s, velocity=70 m/s) [19].
inuence of rubbery plateau modulus and crosslink
density on the erosive wear behavior.
It is ideal when only material composition and testing
conditions serve as ANN input data. As an example,
Fig. 9 shows at a 3-D plot the predicted results for ero-
sion rate as a function of epoxy weight content and
particle impact angle for one type of erodent. Compared
with the real test results (dots in Fig. 9), the predicted
results are very acceptable.
3.2.3. Additional references
Two additional references can be of further help in
the understanding of wear problems of materials using
ANN. They are (1) simulating the tribological proper-
ties of dierent test rigs with various material pairs by
Jones et al., [20], and (2) predicting the abrasive wear
performance of TiN/NbN multi-layers by Rutherford et
al. [21].
3.3. Combined loading situation
An ANN has also been applied by Lee et al. [22] to
failure in combined loading of composite tubes. Biaxial
tests were carried out with cross-ply carbon/epoxy
composite tubes under combined torsion and axial ten-
sion/compression up to failure. Failure strength and
strain were investigated under various biaxial loading
ratios. In total, 43 measured data points were obtained
for the training of the designed ANNs. The axial stress
and the shear stress acted as the ANN input, whereas
the output was a failure vector, FV, dened by
q
FV f2 f2 7
where f is the tensile/compressive failure strength and
f is the torsional failure strength.
The construction of the ANNs was analyzed, and a
two hidden layer ANN (2-[5-5]2-1) with ve neurons in
each layer was nally selected with a satisfactory pre-
dictive quality of the lowest root mean square error
(RMSE). A comparison of the ANN predictive results
with the traditional TsaiWu failure criterion theory
was also carried out, as shown in Fig. 10. It is clear that
the prediction using ANNs has the smallest RMSE
among the models considered.
The paper cited showed some interesting results,
which make it clear that ANNs oer a good possibility
for the prediction of failure data of polymer composites
under dierent loading conditions. However, from the
reviewers point of view, one important ANN problem
should still be considered, which was not mentioned by
the authors. The problem is over-tting as discussed in
Section 2.3. In this paper, all measured data were used
testing. When over-tting occurs, the error on the
 Z. Zhang, K. Friedrich / Composites Science and Technology 63 (2003) 20292044
training set can be driven to a very small value because
of the powerful tting capability of ANNs, but when
new data is subsequently presented to the network, the
error can be large.
3.4. Dynamic mechanical properties
An ANN approach has been proposed for the com-
plex problems of fatigue, wear and combined loading
failure discussed earlier. Nevertheless, it is also interest-
ing for dealing with some relatively simple material
problems, which will be of help to understand the char-
acteristics of ANNs for polymer composite applications.
As an example, Zhang et al. [23] provided an ANN
prediction based on the measurement results of dynamic
mechanical properties (storage modulus and damping)
of short ber reinforced composites in a temperature
range from 150  C to 150  C. A series of polytetra-
uoroethylene (PTFE) based composites blended with
dierent contents of polyetheretherketone (PEEK) and
reinforced with various amounts of short carbon bers
(CF) was considered in this work. Dynamic mechanical
thermo-analysis (DMTA) was employed using a three-
point-bending conguration.
Three material compositions (PTFE, PEEK and short
CF volume contents) and various measuring tempera-
tures were selected as the ANN input parameters, and
the linear viscoelastic properties (storage modulus and/
or damping) acted as output variables. Twenty-ve
neurons were arranged in the hidden layer, and the
Bayesian regularization algorithm was selected which
can automatically identify the optimal size and structure
in the hidden layer. The total number of data was up to
480, consisting of eight kinds of materials with measur-
ing points at every 5 over the total temperature range.
This dataset was divided into a training dataset and a
test dataset. The number of training data was rstly
Fig. 10. Comparison of predictions with experimental data under
combined axial and torsional loading of composite tubes [22].
2039
investigated, since it strongly inuences the
predictive quality. Fig. 11 gives the percentage of test
data B-values in the range of B50.9 [calculated by Eq.
(5)] in comparison to the number of training data. The
dots refer to calculated results for the storage modulus
and the damping (loss factor), respectively. It can be
clearly seen that an increase in the number of training
data improves the predictive quality for both the storage
modulus and the damping, but the number required to
reach a perfect predictive quality are dierent for these
two output parameters. To approach 100% of the test
data with a predictive quality of B50.9, needs only 40
randomly selected training data for the dynamic mod-
ulus. However, for a similar quality in the prediction of
the damping factor, more than 120 training data are
needed. From this it can be concluded that the modulus
has a stronger relationship to temperature and material
composition than the damping factor. In other words,
the nonlinear dependency of damping characteristics is
greater than that of the storage modulus. Therefore, an
ANN requires more experience in learning the more
complex nonlinear relationship for the damping than
that for the modulus.
In Fig. 11, the dependence of the fraction of the test
data with B50.9 on the number of training data for a
two-output ANN (modulus and damping) was also
compared with the results for a one-output ANN. The
quality of the two-output neural network is lower than
that of the one-output ANNs for damping when the
same number of data was used for training. The reason
is that with a multi-output network, the ANN inter-
neuron weights need to t the relationships for all the
output variables in the learning process. This is why
more training data are needed to reach a similar pre-
dictive quality to that in a one-output ANN. Therefore,
before sucient training data are available, it is recom-
mended that a one-output network should be always
Fig. 11. Dependence of the percentage of test data with a B-value in
the range of 0.91.0 on the number of training data for modulus and
damping, respectively [23].
2040 Z. Zhang, K. Friedrich / Composites Science and Technology 63 (2003) 20292044
considered rst in practical applications of polymer
composites, in order to reach a higher predictive quality.
3.5. Processing optimization
The building of models or simulations for composite
processes oers many benets. These include [24]: (a)
forecasting the output from untried combinations of
parameter values, (b) unlimited experimentation and
searching at low cost, (c) process improvements through
studying the model, (d) minimized downtime for trials,
(e) training for operatives, and (f) investigation of
hazardous events.
A neural network has been utilized by Allan et al. [24]
to predict the structure and properties of polypropylene
bers, which could be helpful to identify the control
parameters in manufacturing. Some key manufacturing
parameters, i.e. temperatures and speeds of the rollers
and plates, were selected as the ANN inputs, and the
outputs were the ber properties, tenacity, elongation,
modulus, shrinkage, crystal order and orientation,
which mainly concern the quality of the bers. The
predictions were based on a 6-[2]1-1 or 6-[3]1-1 con-
guration of a multi-layered ANN, and several
encouraging results were obtained which showed that
the ANNs were able to generalize quite well in the
simulation of manufacturing processes. In this study, a
Kohonen self-organizing map type of neural network
was applied to classify the measured dataset. Another
approach in a similar direction was performed for the
optimization of the polymerization process of poly-
amide 6.6 by Nascimento and Giudici [25].
Heider et al. [2628] applied ANN modeling for real-
time simulation of the automated thermoplastic com-
posite tow-placement system. Both a cerebellar model
arithmetic controller and feed-forward ANNs were
considered. The rst principle physics based models, e.g.
heat transfer, consolidation, and bonding condition,
were employed as ANN inputs to predict part quality
outputs, e.g. void content, and degree of bonding.
Excellent accuracy was achieved. Furthermore, ANNs
were also used to optimize the process conditions, e.g.
heat input and velocity, to achieve desired quality, e.g.
less than 1% void content, and high than 90% bonding.
This was extended to incorporate the eects of multiple
passes of heat and pressure and can show how the
properties evolved during the process. ANNs also
exhibited excellent ability to provide feedback rapidly in
very complex simulation, which was the key to use it for
process control. To conclude, these work presented
good examples for applying ANNs in composite process
optimization and control.
In order to improve the manufacturing aordability
and quality of thermosetting composite materials, sev-
eral research eorts have been devoted to developing
numerical process models for obtaining optimal cure
cycles. However, a rapid cure simulation method was
still needed for online process control. Rai and Pitch-
umani [2931] proposed a simulation approach based
on an articial neural network. A typical four-stage cure
temperature cycle of thermosetting composites was
considered, for which the four stage-end-temperatures
and their constant stage duration, as well as the lami-
nate thickness were the six input data of a multi-layer
feedforward network. The ve output data of the net-
work were the maximum laminate temperature, the
maximum temperature dierence, the maximum gra-
dient, the minimum degree of cure, and the cure time.
Two optimized network architectures, 6-[25]1-5 and
6-[15-7]2-5 were nally selected. The predictive cap-
ability was assessed by using the network to simulate
5000 cases of cure processes with various cure cycles
and laminate thickness. These 5000 training and test
datasets were obtained from numerical models for the
kinetics for a wide range of cure temperature cycles and
parameters. It was shown that the optimal cure cycles of
the ANN prediction were reasonably accurate in com-
parison of the mean-square-error to the results based on
the numerical process models. The use of the neural
network in lieu of the numerical models reduced the
computational time for process simulations by several
orders of magnitude, which oered the possibilities of
on-line monitoring and control of composite curing.
Su et al. [32] used predictions made with ANNs to
monitor the curing process of graphite ber reinforced
epoxy. A recurrent neural network (RNN) was applied,
which comprises neurons and synapses similar to those
of a feedforward network, except that the information
ows not only in the forward direction but also in the
backward direction along the synapses. This has an
advantage in dealing with some time-reacted para-
meters. The degree of cure as a neural network output
was predicted by various input parameters for the cure
cycles, i.e. the dimensions of the composite laminates,
heat of cure reaction, initial resin contents, and cure
schedules. A network architecture of 6-[8]1-1 was opti-
mized. Two additional experiments demonstrated the
eciency of this approach.
ANNs were also utilized by Wagner et al. [33], as well
as by Li and Bridgwater [34], to model extrusion pro-
cesses. It turned out that here also the predictions
showed signicant potential for an optimization of these
processes because of the characteristics of ANNs that
the simulations are directly based on experimental
datasets, without any prior assumptions about the rela-
tionships between the input and output variables.
3.6. Other related applications
Conventional optimization methods for composite
structures usually involve the development of step-by-step
procedures and their implementation into a larger com-
 Z. Zhang, K. Friedrich / Composites Science and Technology 63 (2003) 20292044
puter program. The application of an ANN approach
oers, on the other hand, a new route in which a large
number of simple processing units is directly connected
within the network structure by means of weights. An
ANN has, in addition, the capability to learn the
underlying principles involved in solving the optimiza-
tion problem, from examples by adjusting these weight
factors. After a well-trained ANN is obtained, it can
then be used to tackle similar problems in optimal
design of composite structures. Jayatheertha et al. [35]
proposed an application of articial neural networks to
the optimum design of a laminated plate. Other work
concerning this approach includes: a thick composite-
beam model for delamination prediction by Valoor and
Chandrashekhara [36]; the self-adaptive vibration con-
trol of smart composite beams using recurrent ANNs by
Valoor et al. [37]; the estimation of contact force on
composite plates using impact-induced strain by Chan-
drashekhara et al. [38]; the characterization of high-
velocity impact damage in advanced composite plates
using multi-sensing techniques by Okafor et al. [39]; the
damage assessment of composite structures using a
fuzzy logic integrated ANN by Ramu and Johnson [40];
the eective response of random composites by Gotlib
et al. [41]; and the rational design of polymeric materials
with the example of new polycarbonates by Ulmer et al.
[42].
Compared with polymer composites, more research
works has been carried out on metals and other materi-
als with articial neural networks. These include: the
predictions of timetemperaturetransformation dia-
grams in titanium alloys by Malinov et al. [43]; fracture
toughness in microalloy steel by Haque and Sudhakar
[44]; wear particle analysis by Umeda et al. [45]; wear
debris classication by Myshkin et al. [46]; high-tem-
perature mechanical behavior of concrete by Mukherjee
and Biswas [47]; fracture of cementations by Arslan and
Ince [48]; macro-mechanical behavior of ceramic-matrix
composites by Rao and Mukherjee [49]; strength prop-
erties of lateritic soils by Attoh-Okine and Fekpe [50];
reduction of corrosion data by Cottis et al. [51], and
kinematic hardening simulations by Huber and Tsak-
makis [52,53]. It should be emphasized that the principles
and some results from these references could also be
applied, to some extern, in predicting the performance of
polymer based composites.
Bhadeshia [54] generally reviewed the neural networks
in materials science in a special issue of ISIJ Interna-
tional. Other reviews concerning ANN applications in
(1) mechanics by Zeng [55], (2) industrial processes by
Swingler [7], Lennox et al. [56], and Du and Wolfe [57],
respectively, (3) the determination of computer numeri-
cal control of machining parameters by Park and Kim
[58], (4) the utilization in energy system by Kalogirou
[59], could oer additional guidance in the implemen-
tation of this versatile mathematical tool in engineering
2041
science in general, and polymer composites in parti-
cular.
4. Additional remarks
4.1. Input parameters
Properly selected input parameters can be of help to
reach a satisfactory predictive quality with a relatively
small training dataset. When comparing the two exam-
ples of fatigue life prediction, it can be seen that the use
of ber orientation as input data is able to achieve quite
high predictive quality with a training set of only 92
data, taken from unidirectional composites [10], and the
result is even better than the one achieved in Ref. [8]
with more than 400 data, taken from laminates.
Unquestionably, the fatigue life of laminates in the lat-
ter case is much more complicated than that of uni-
directional ones, which will also demand more training
data to teach the neural network to accurately under-
stand relationships behind. Nevertheless, the composi-
tion parameter seems to inuence the performances of
polymer composites strongly. This can, in addition, be
observed clearly from the wear prediction of Fig. 5. To
involve the composition contents of short ber compo-
sites as input parameters increases the predictive quality
signicantly, which makes it clear that the selection of
the input parameter plays a key role to the ANN
approach.
4.2. Number of neurons in the hidden layer
The powerful function of an ANN is due to the neu-
rons within the hidden layers, as well as to the related
interconnections. It is believed that an ANN can repre-
sent any reasonable relationship between input and
output if the hidden layers have enough neurons. How-
ever, for the practical case, more hidden neurons bring
more interconnections, which require, in turn, larger
training datasets for learning the relationships. It is
therefore always necessary to optimize the numbers and
congurations of the ANN hidden layers, as demon-
strated by several of the references in this review. Some
experimental results have suggested that the optimum
ANN architecture contains a ratio of three [8] or four
[10] hidden neurons to every input node of networks
with one hidden layer. Nevertheless, a multi-hidden-
layer ANN is sometimes also of great advantage
[17,22,26]. The Bayesian regularization oers the cap-
ability to automatically identify the optimal size of the
ANN in its hidden layer.
A further point is of interest. A very simple ANN
conguration was employed to predict the abrasive wear
performance of TiN/NbN multi-layers by Rutherford et
al. [21]. An 8-[3]1-1 ANN was chosen for predicting the
2042 Z. Zhang, K. Friedrich / Composites Science and Technology 63 (2003) 20292044
wear resistance and an 8-[6]1-1 ANN for the hardness,
based on an initial database of 42 coating systems.
Details about the evaluation method were not included
in this publication. To analyze the eect, the reviewers
also tried to use such a simple conguration, i.e. 9-[4]1-
1, with the dataset mentioned in Ref. [17] to predict the
specic wear rate. In fact, this conguration sometimes
gave good output results with a high predictive quality,
i.e. about 40% of the test data with B-values in the
range of 0.91.0. However, the stability was not good,
which means that when the random selection of the test
datasets was randomly selected 50 times, the quality
could sometimes be very poor. On the other hand, this
is not true for the three hidden layers ANN congur-
ation [17], in which the B distributions are very stable
and of a high predictive quality. The reason for the
instability of the simple ANN conguration is not clear,
but one should always consider that an ANN is inspired
by our biological neural system. In human beings,
someone can learn very fast and reach the right solution
even with only a little information. Nevertheless, this
simple neural network conguration oers an option
with quite short computing time and a relative small
training dataset, which will be certainly useful for the
prediction of online monitoring of much simpler rela-
tionships in practical applications. A similar archi-
tecture has also been used in Ref. [24] to predict the
control parameters in the manufacturing of
polypropylene bers.
4.3. Size of the training dataset
The size of the training dataset is a very sensitive
question in the practical applications. To reduce the
number of the data required, much eort has been made
to investigate the inuences of various ANN archi-
Fig. 12. Dependence of the percentage of test data with a B50.9 on
the number of training data of various ANN output, i.e. the tensile
strength, complex modulus, tensile failure strain, impact strength and
specic wear rate [18].
tectures and input parameters. However, one should
always consider that the characteristic of the ANN
approach is to simulate complex nonlinear relationships
between given input and output data, based on various
amounts of measured datasets. Therefore, the data
required for training should also depend on the rela-
tionships simulated. Fig. 12 shows a comparison of the
predictive qualities of various mechanical properties as
ANN outputs. The dataset is the same as that used in
Ref. [17], i.e. only material compositions and measuring
conditions were used as input. The Bayesian regulariza-
tion is used in all these calculations, with a one-hidden-
layer architecture of 25 neurons. It can been seen that
the tensile strength and the complex modulus can be
rather easily simulated, since fewer than 70 training data
were needed to reach a high quality of 100% for the test
data with a B50.9. However, to achieve a similar pre-
dictive quality, the tensile failure strain and the impact
strength require about 90 data to train a similarly
structured neural network. The most complicated case
was found for the specic wear rate. 88 training data
could only yield a quality of 38% of the test data B-
value to be higher than 0.9, and therefore more mea-
sured data were still needed to simulate the wear prop-
erties in the present case more accurately. It is clear that
the static strength and modulus have a closer relation-
ship with the material composition, since these proper-
ties can be predicted theoretically according to the rule
of mixtures. The relationships of tensile failure strain
and impact strength to the input parameters are
more complex, and wear is undoubtedly the most
complicated.
The analysis shows that the number of training data
plays a key role in determining ANN predictive quality.
It can be concluded that the more complex the non-
linear relation between input and output is, the larger is
the training dataset required. It is generally believed
that these neural networks are able to approximate any
reasonable function with enough parameters. It can
therefore be expected that in most cases of the proper-
ties of polymer composites, a perfect ANN prediction
can be achieved so long as sucient measuring data are
available.
5. Conclusions
Evolving from neuro-biological insights, the neural
network approach gives a computer system an amazing
capacity to actually learn from input data. An ANN is
ideally suited for simulating complex polymer compo-
site problems because, like its biological counterparts, it
can learn, and therefore can be trained to nd solutions.
In contrast to classical approaches in composite model-
ing, neural networks require no explicit mechanistic
model or restrictive assumptions of normality or linear-
 Z. Zhang, K. Friedrich / Composites Science and Technology 63 (2003) 20292044
ity. The following conclusions can, therefore, be drawn
from the present review:
1. Composite design: It is ideal in polymer composite
design when only material compositions and test-
ing conditions serve as ANN input data. A well-
trained ANN is expected to be very helpful to
predict the material properties before manufactur-
ing/testing the real composites.
2. Processing optimization: There are many para-
meters in the manufacturing processes that control
the nal qualities of the polymer composites.
ANNs could be of help to simulate the relationships
between these manufacturing parameters and the
material performance, which can be used as the basis
for a computer-based processing optimization.
3. Property analysis: The analysis of relationships
between some simple properties and other complex
properties (e.g. the ranking of the importance in
Ref. [19]) will be of additional help in the design of
new composite materials. The simple properties
are normally easier to obtain than complex ones,
and therefore successful prediction could be of
benet to reduce the number of more complex
experiments.
4. Size of the training dataset: The required number
of training data can be reduced by optimizing the
neural network architecture and by choosing sui-
table input parameters. However, the more com-
plex the nonlinear relation between input and
output is, the more training data are required.
The applications of ANNs to polymer composites are
still in their basic stages, which means that the investi-
gations of the implementation possibilities in dierent
material research areas and the improvements of the
predictive qualities are still matters for further research.
It is an intention of the present review to promote wide
consideration of the use of the articial neural network
approach in polymer composites research.
Acknowledgements
The project was supported by the Alexander von
Humboldt Sofja Kovalevskaja Award program,
nanced by the German Federal Ministry of Education
and Research (BMBF) within the German Govern-
ments ZIP program for investment in the future.
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