CHAPTER 6 – BDA 20402

Non metallic materials

~ COMPOSITE ~

6.7 INTRODUCTION
6.8 PROCESSING/FABRICATION
6.9 SELECTION OF POLYMER, CERAMIC AND COMPOSITE
 6.7 Introduction

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Hybrid Materials

Steels
Cast Irons
Al-Alloys
Metals
Cu-alloys
Zn-alloys
Ti-alloys

PE, PP, PET, PC, PS,

Aluminas PEEK, PA (nylons)
Silicon Carbides POLYMERS
CERAMICS Polyesters
Silicon nitrides Phenolics
Composites
Zirconias Epoxies
Sandwiches
HYBRIDS
Segmented structures,
Lattices and foam

Isoprene
Neoprene
Soda glass
Butyl rubber
Borosilicate glass
Elastomer Glasses Hybrid materials combine the
Natural rubber properties of two (or more)
Silica glass
Silicones
EVA
Glass-ceramics monolithic, materials, or of one
material and space [Ashby, 2017]

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Holes in Materials – Property Space
Approach to filling holes;

1. Developing new
materials - alloy
compositions, polymer
chemistries, new
compositions of glass
and ceramic.

2. Combine two or more

existing materials – to
allow a superposition of
their properties – create
hybrids.
(Success in developing
CFRP and foams)

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Hybridization Scenarios [Ashby, 2017]
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- Hybrid Design
WHY aren’t the properties
of the resulting hybrid
simply the sum of those of
the ingredients each
weighted by it volume
fraction?
- Some properties follow the
‘rule of mixtures’: the
density, specific heat &
dielectric constant.
- Others combine in the
other ways – depends on
the configuration of the
materials and the way they
are combined.
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Structural hybrid – particulate and fibrous composites.

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• Macroscopic combinations of metallic, ceramic, and/or polymeric
materials having an identifiable interface between them.
• It has characteristics that are not depicted by any of the components in
isolation.

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1) Matrix
• Matrix serves as continuous phases.
• Purpose:
(i) binding the reinforcement phase in place
(ii) deforming to distribute the stresses among the constituent reinforcement
materials under an applied force

2) Reinforcement
• Purpose of reinforcing constituents in composites
(i) enhance matrix properties – provide strength, heat resistance/conduction,
corrosion resistance, rigidity.
(ii) must be stronger and stiff than matrix & capable of changing failure
mechanism.

3) Interface
• The interface is a bonding surface or zone where a discontinuity occurs, whether
physical, mechanical, chemical etc.
• Bonding with the matrix can be either weak Van der Walls forces or strong covalent
bonds.

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 Types of composites
• Composite are classified firstly according to the matrix.

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 Types of composites
• In addition – classified according to the types (form) of
reinforcements or fillers used.

* particles in form of rods, * reinforcement is planar in

spheres, flakes or others. form - produced by stacking
the layers or plies.

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 Structures, reinforcements, types and properties of composites

Structure Reinforcement Composite Properties

Particle Particulate Isotropic

Short/chopped Discontinuous Random – isotropic

fibers fiber Aligned - anisotropic

Continuous Continuous Orthotropic

fiber fiber

Laminae of Laminar Through - thickness

layers laminates anisotropy;
Planar – isotropy/anisotropy

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ISOSTRAIN CONDITIONS (LONGITUDINAL LOADING)

- In this case the stress on the material causes uniform strain on all the
composite layers.
- Assume the bonding between the layers remains intact during the stressing.

  
c m f
E E V E V The rule of mixtures
c m m f f # for binary
composites

Ff E fVf
 where
Fm EmVm  , , strain
c m f
 c , m , f  stress
 , ,  Modulus Young
c m f
c composite
m  matrix
f  fibre

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ISOSTRESS CONDITIONS (TRANSVERSE LOADING)

• The load is applied at a 90 angle to the direction of fiber alignment as

shown in Figure below.
• The stress  to which the composite as well as both phases are exposed is
the same.

 c  m  f

E E
m f
E 
c V E V E
m f f m

where
Lc - composite elongation
Lm -matrix elongation
L f -fiber elongation

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 COMPOSITE BENEFITS
• CMCs: Increased toughness • PMCs: Increased E/r

• MMCs: Increased creep resistance

Adapted from T.G. Nieh, "Creep rupture of a

silicon-carbide reinforced aluminum
composite", Metall. Trans. A Vol. 15(1), pp.
139-146, 1984. Used with permission.

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 6.8 Fabrication of
Composites

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 Methods of Composites Fabrication

• PMC (Polymer Matrix Composites)

1) Hand Lay-Up Method
2) Spray-Up Method
3) Filament winding
4) Pultrusion
5) Compression molding
6) Vacuum Bagging/Autoclaving
7) Wet flow methods – Injection molding, Resin
transfer molding

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 (a)

(b)
Hand Lay-Up Method
(a) Pouring the resin over the reinforcement in the mold.
(b) Use of the roller to densify the laminate to remove entrapped air.

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Filament Winding Process
The fibers are first impregnated with plastic
resin and then wound around a rotating
mandrel (drum).

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Pultrusion process
Fibers impregnated with resin – fed into a heated die – slowly drawn out as a cured
composite material with a constant cross-sectional shape.

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 6.9 Selection of
Composite

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Properties - selection of composite materials

Hybridization – gives a way of

creating controlled anisotropy.

Properties;
• Strength
• Thermal expansion coefficient
• Thermal conductivity
• Thermal diffusivity
• Dielectric constant
• Electrical conductivity and
percolation
Failure modes in composites (A) fibrous
composites and (B) particulate composites
[Ashby, 2017]

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Composite Design – Stiffness at Minimum Mass

Part of the E-r property chart, showing Al alloys, Be and Al2O3. Bounds for the moduli of hybrids made by
mixing Al with the other two are shown. The diagonal contours plot the criterion of excellence for a light,
stiff beam [Ashby, 2017].

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Composite Design – Controlled Thermal Response

A part of expansion-coefficient
/conductivity space showing Al
alloys, boron nitride and SiC. The
Al-SiC composites enhance
performance, the AL-BN
composites reduce it [Ashby,
2017].

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Filling Property Space with Composites

Polymer (PMC) and Metal (MMC) matrix composites expand the occupied area of modulus-density
space. Data from the CES EduPack 2016 [Ashby, 2017].

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 Polymer (PMC) and Metal (MMC) matrix composites also expand the occupied area of strength-
density space. Data from the CES EduPack 2016 [Ashby, 2017].

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