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D. Fiber-Reinforced Composites
In fiber-reinforced composites,
continuous or discontinuous thin
fibers of one material are embedded
in a matrix of another. The objective is
usually to enhance strength, stiffness,
fatigue resistance, or strength-to-
weight ratio by incorporating strong,
stiff, but possibly brittle, fibers in a
softer, more ductile matrix.
Fiber-Reinforced Composites …2
rocket nozzle
surgical implants clutch
D.4. Ceramic-Matrix Composites
Ceramic-matrix composites (CMCs)
offer light weight, high-temperature
strength and stiffness, and good
dimensional and environmental
stability. The matrix provides high
temperature resistance.
Ceramic-Matrix Composites …2
Glass matrices can operate at
temperatures as high as 1500ºC
(2700ºF). The crystalline ceramics,
usually based on alumina, silicon
carbide, silicon nitride, boron nitride,
titanium diboride, or zirconia, can be
used at even higher temperatures.
Ceramic-Matrix Composites …3
The fibers add directional strength,
increase fracture toughness, improve
thermal shock resistance, and can be
incorporated in unwoven, woven,
knitted, and braided form. Typical
reinforcements include carbon fiber,
glass fiber, fibers of the various matrix
materials, and ceramic whiskers.
Ceramic-Matrix Composites …4
Applications:
Composites with discontinuous fibers
tend to be used primarily for wear
applications, such as cutting tools,
forming dies, and automotive parts such
as valve guides. Other applications
include lightweight armor plate and
radomes.
Ceramic-Matrix Composites …5
Continuous-fiber ceramic composites
are used for applications involving the
combination of high temperatures and
high stresses. Examples include gas-
turbine components, high-pressure heat
exchangers, and high-temperature
filters.
Disadvantage:
high to extremely high cost
Ceramic-Matrix Composites …6
E. RMC Fabrication Process
Fabrication processes for resin-matrix
composites involve some form of
molding, to shape the resin and
reinforcement. A mold tool is required
to give the unformed resin /fiber
combination its shape prior to and
during cure.
RMC Fabrication Process …2
The most basic fabrication method for
thermoset composites is hand layup, which
typically consists of laying dry fabric layers,
or “plies,” or prepreg plies, by hand onto a
tool to form a laminate stack. Resin is
applied to the dry plies after layup is
complete (e.g., by means of resin infusion).
In a variation known as wet layup, each ply
is coated with resin and “debulked” or
compacted after it is placed.
RMC Fabrication Process …3
Several curing methods are available.
The most basic is simply to allow cure
to occur at room temperature. Cure
can be accelerated, however, by
applying heat, typically with an oven,
and pressure, by means of a vacuum.
RMC Fabrication Process …4
For the vacuum process, a vacuum bag,
with breather assemblies, is placed over
the layup and attached to the tool, then
evacuated using a vacuum pump before
cure. The vacuum bagging process
consolidates the plies of material and
significantly reduces voids due to the off-
gassing that occurs as the matrix
progresses through its chemical curing
stages.
RMC Fabrication Process …5
Many high-performance thermoset
parts require heat and high
consolidation pressure to cure —
conditions that require the use of an
autoclave, a strong, heated container
used for chemical reactions and other
processes using high pressures and
temperatures.
●● End of Lecture 26
●●● End of Lectures