Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
TOPIC 10.
10 COMPOSITE MATERIALS (S
(Session
i I)
Introduction
Concept of composite materials
Constituents of composite materials
Classification of composite
p materials
Why polymers are used in Composite Materials?
Reinforcements
Particles
Fibers
Mechanical properties of different reinforcement materials
Laminated Structures
Dpt. Materials Sci. and Eng. and Chemical Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Concept of composite materials
What is a composite material?
• Wood • Concrete
• Hypoeutectoid steel
• Austenitic stainless steel
? • Reinforced concrete
• Cement
p
• Cellophane
• Paper
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Concept of composite materials
What is a composite material?
material?- The result from a “clever”
clever combination of two or more different
materials
SYNERGYSM All kinds of Advanced
ANISOTROPY
INTERFACES Composites Composites
SYNERGISM: The overall performance of the material should be better than the separate
components for a particular applications. Properties vary continuously over a range.
When composites are extremely anisotropic, with hard interphases (large gradient in
composition and properties) and designed for structural applications: Advanced Composite
Materials.
When a composite
p is made of long
g and extremelyy stiff reinforcement FIBRES aligned
g in specific
p
directions and immersed in a polymer MATRIX: Advanced Polymer Composite Material.
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Concept of composite materials
COMPOSITES IN NATURE
Abalone shell:
CaCO3
+ 3% organic material
>3000* stronger than calcite
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Constituents of composite materials
1. Reinforcement / Fibres:
The reinforcements impart their special mechanical and physical properties to
enhance the matrix properties.
p p
INTERFACE: The planar region that separates two components in any material. Is
regarded as the third phase in the composite because the matrix structure is modified
close to the fiber surface.
surface
Both the fiber and matrix can be a polymer, a metal or a ceramic. The properties of
p
composites are a function of the p properties
p of the constituent p
phases, their relative
amounts, and the geometry of the dispersed phase.
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Constituents of composite materials
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Classification of composite materials
Composite: A multi-phase material that exhibits a significant proportion of the properties of the constituent
phases such that a better combination of desirable properties is realized.
Matrix: The continuous phase that surrounds the other constituents and binds them into a composite
material.
Dispersed Phase: The discontinuous, or discrete phase that adds reinforcement to the composite.
Particle: A relatively short globular or spherical dispersed phase.
Fiber: A reinforcement, typically cylindrical, with a diameter smaller than its length
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Classification of composite materials
According to the reinforcement:
COMPOSITE MATERIALS
Large- Dispersion
Large Nanoparticles Laminates Sandwich
particle strengthen panels
aligned Randomly
oriented
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Why polymers are used in Composite Materials?
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Why polymers are used in Composite Materials?
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Why polymers are used in Composite Materials?
• Costly
y programs
p g for evaluation,,
and certification of structures
• Costly investments for installations
and equipment
• High material cost
• Water entry in sandwich structures
• Low
L impact
i t resistance
i t COMPONENT
DETAILS
COUPONS
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Why polymers are used in Composite Materials?
The application of composites in place of metals requires different approaches to the design and
service of structural components. Labour intensive manufacturing, expensive raw materials,
damage tolerance aspects, and the need for new inspection and repair philosophies that need
to be addressed The factors currently driving new materials applications on commercial aircraft
will place added emphases on
• Design simplification,
• Low-cost processing
• Durability
• Maintainability
•
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Why polymers are used in Composite Materials?
The aerospace sector with the highest interest in lightweight design is of course the space
industry. A kilogram saved can have a value of more than €10000. Therefore, high modulus
carbon fibres are the most important candidates for structural space materials. In addition to
their mechanical performance,
performance the low coefficient of thermal expansion of carbon fibre
reinforced plastics is highly relevant for satellite applications. One use of composites in space
applications is the carbon/carbon technology employed, for example, as the heat shielding
material of re-entry structures or rocket nozzles
.
A sandwich
d i h structure
t t f ultralight
for lt li ht solar
l panels.
l The
Th skin
ki consists
i t off high
hi h modulus
d l carbon
b fibres
fib
produced by a special filament winding technique. The core is extremely light aluminium honeycomb.
T9 -
13
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Reinforcements
REINFORCEMENTS
Particles (dispersion strengthened - large particles -nanoparticles)
Fibers (discontinuous - short or continuous – aligned- woven)
Structural (laminates and sandwich structures)
concentration size
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Reinforcements: Particles
General aspects of particle reinforced composites:
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Reinforcements: Particles
Ceramic particles
To select the appropriate reinforcement it should be
taken into account:
Structural Particle
High modulus
Low density
Particle shape (avoid corners)
Thermal:
Expansion coefficient and conductivity Properties of SiC and Al2O3 particles:
System
y Application
pp
Ag-CdO Electrical connectors
Al-Al2O3 Nuclear reactors
Be-BeO p
Nuclear reactor and aerospace
Co-ThO2,Y2O3 Magnetic materials resistant to yield
Ni-20% Cr-ThO2 Turbojet components
Pb-PbO Batteryy grid
g
Pt-ThO2 Wires, electrical components
Examples and applications of dispersion strengthened compounds
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Reinforcements: Particles
C
Composite materials reinforced
f with large particles
Large particles of a hard and brittle material uniformly scattered in soft and ductile
matrix. Meso-micro scale. The reinforcement bears or helps to bear the load.
These composites are designed to produce unusual properties and not to improve
strength
Metals and ceramics particles are added to improve toughness and mechanical resistance
Plastics particles are added as a filling to improve properties (carbon black - soot, elastomers) or
reduce cost (CaCO3, clays, hollow glass spheres…)
CONCRETE. It is a matrix of cement together with gravel or sand particles. “It is a composite of particles
held together by cement”. Fine aggregate cement (sand), coarse aggregate (gravel) and water
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Examples: Particle Reinforced composite
1 m WC–Co
Carbon Black particle cemented carbide
carbide. Light
reinforcement in Styrene- areas are the cobalt matrix;
dark regions, the particles of
Butadine synthetic rubber for
tungsten carbide x100.
car tire application.
application
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Reinforcements: Fibers
FIBER-REINFORCED COMPOSITE MATERIALS
Transversal
direction
Di ti
Discontinuous d
and Discontinuous and
aligned fibers randomly places fibers
Types of fibers:
Glass fibres ((GFRP))
Carbon fibres (CFRP)
Aramide (AFRP)
Other fibers: boron, SiC, Al2O3
Role of the fibers. Bear most of the load applied to the composite
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Reinforcements: Fibers
Glass fibres
Used to reinforce plastic matrixes
Composition: Base of SiO2 (50-70%) + Oxides Ca, Al, B, Na, Mg and K
Properties: non combustible,
combustible good chemical, ↑ ↓)
chemical biological and thermal resistance (Tm↑,↓),
thermal insulator (K↓), electric insulator (↓), low expansion coefficient and low cost
Strength of glass fibres is determined by: damage during processing, and the adsorption
of water over their surface
• The strength of these fibers is high but not extreme: there are limits in their application
• E glass is the cheapest and has the highest moisture resistance (polymeric matrixes)
Material, % in weight
Type
yp of Secondary
y
Sili
Silica Al i
Alumina C O
CaO M
Magnesium
i B2O3 N 2CO3
Na C F2
CaF
glass Oxides
E (1) 54 14 20,5 0,5 8 1 1 1
A (2) 72 1 8 4 - 14 - 1
ECR 61 11 22 3 - 0,6 - 2,4
S (3) 64 25 - 10 - 0,3 - 0,7
(1) Ca Aluminoborosilicate
(2) Rich in alkali
T
Types and
d composition
iti off different
diff t fiberglass
fib l
(3) Mg Aluminosilicate without B
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Reinforcements: Fibers
Glass fibres
Fiberglass properties
Type tensile
E (GPa) (K)10
-6
of relative (MPa) ((a 20 ºC y 1 Tm (ºC) For applications that require
glass MHz)
a) Continuous fibers
b) Discontinuous Glass fabric
c) Woven fiber (dry or prepeg)
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Reinforcements: Fibers
Carbon fibres
Evolution of the applications of carbon fiber during the period 2001-2010 source: M. Kamiura. Toray Carbon
Fiber Composites Materials Businesses. oray IR Seminal-No.7. June 6, 2005)
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Reinforcements: Fibers
C b fibres:
Carbon fib IUPAC classification
l ifi ti (according
( di tot mechanical
h i l properties)
ti )
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M (www.carbonfiber.gr.jp). Aerospace Materials I
Topic 10: Composite Materials
Reinforcements: Fibers
• nanotubes:
promissing reinforcements
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Reinforcements: Fibers
Carbon fibres
Manufactured from organic precursors:
Polyacrylonitrile (PAN –based fibers) (E and tensile strength)
Pitch (Pitch-based fibers) (ioll/coal precursor): Isotropic (E) or anisotropic (mesophase)
(E and tensile strength)
Unidirectional
U idi ti l
tape
Bundles or tows Coil
Individual 1K (1000 filaments)
filaments 3K (3000 filaments)
(5-20 μm) 6K (6000 filaments)
12K (12000 filaments)
24K (24000 filaments)
K cost
Fabric
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Reinforcements: Fibers
Carbon Fiber Products and Usage
Types Specifications Major Usage
Fillament A yarn constituted of numerous number of fibers: twisted, Resin reinforcement material for CFRP, CFRTP or C/C
untwisted, twisted-and-untwisted composites, having such usage as Aircraft/Aerospace
equipment sporting goods and industrial equipment parts
equipment,
Tow An untwisted bundle of yarn constituted of extremely Resin reinforcement material for CFRP, CFRTP or C/C
numerous number of fibers composites, having such usage as Aircraft/Aerospace
equipment, sporting goods and industrial equipment parts
Staple Yarn A yarn made of spinning of staples Heat Insulator, Anti-friction material, C/C composite parts
W
Woven ffabric
bi A woven sheet
h t made d off filament
fil t or staple
t l yarn R i reinforcement
Resin i f t material
t i l ffor CFRP,
CFRP CFRTP or C/C
composites, having such usage as Aircraft/Aerospace
equipment, sporting goods and industrial equipment parts
Braid A braided yarn made of filament or tow Resin reinforcement material particularly suitable for
reinforcement of tubular products
C
Chopped f
fiber A chopped fiber
f made off sized or non-sized fiber
f C
Compounded into plastics/resins
/ or portland cement to improve
mechanical performances, abrasion characteristic, electric
conductivity and heat resistance
Milled Powder made by milling fiber in a ball-mill etc. Compounded into plastics/resins or rubber to improve
mechanical performances, abrasion characteristic, electric
conductivity
d ti it and dhheatt resistance
i t
Felt.Mat A felt or mat made by layering up of staple by carding etc. Heat insulator, base material for molded heat insulator,
then needle-punched or strengthened by organic binders protective layer for heat resistance and base material for
corrosion-resisting filter
Paper A paper made from staple by dry or wet paper-making Anti-electrostatics sheets, electrodes, speaker-cone and heating
plate
Prepreg An intermediate material in a form of half-hardened Aircraft/Aerospace equipment, sporting goods and industrial
sheets made of Carbon Fibers impregnated with thermo- equipment parts needing lightness in weight and high
setting resin, qualities of which being stable and performances
sustained long enough and therefore easily applicable for
automatic
t ti sheet-layering
h tl i
Compounds A material for injection moulding etc. made of mixture of Housing etc. of OA equipment taking advantages of electric
thermo-plastics or thermo-setting resins added by various conductivity, rigidity and lightness in weight
additives and chopped fiber and then being compounded
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Reinforcements: Fibers
Carbon Fiber Products
Fillament Woven fabric Braid
Tow Staple Yarn
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Reinforcements: Fibers
Carbon Fiber Products
Filament Number of
Type Modulus Mean elastic
Symbol Filaments Modulus (GPa)
3K 3000
6K 6000
Standard 230
12K 12000
24K 24000
6K 6000
Convencional tows
intemediate 12K 12000 300
24K 24000
6K 6000
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Reinforcements: Fibers
Fabrications methods and applications for the different types of carbon fiber products
Fillament
Woven fabric Prepreg Chopped fiber
Types
Applications
Pressure Car bodies, Aircrafts
Vessels ships Aircrafts Sports Computers
Aircrafts equpment
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Reinforcements: Fibers
Aramid fibres
Kevlar polyamide (poly(paraphenylene terephthalamide ))
The aromatic ring provides thermal stability
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Reinforcements: Fibers
Boron fibres
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Reinforcements: Fibers
Ti3Al
M i
Matrix
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Reinforcements
Types of fiber fabric:
BID (bi-directional): cloth has half of the fibers woven parallel to the selvage edge of the cloth
and the other half at right
g angles
g to the selvage,
g g givingg the cloth the same strength
g in both
directions
UND (uni-directional): cloth has 95% of the glass fibers woven parallel to the selvage, giving
exceptional strength in that direction and very little at right angles to it
weft warp
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Reinforcements
Types of fiber fabric:
CARBON, GLASS, ARAMID, and other multi-filament fibers are produced in various fabric forms for
processing into high-perfomance PMCs using pre-preg, resing film or liquid resin injection techniques
woven
fibers
Plain weave
8 HS (harness satin) 0.5 mm
cross
section
view 0.5 mm
4 HS (harness satin) 2x2 twill From D. Hull and T.W. Clyne, An Introduction to
Composite Materials, 2nd ed., Cambridge
University Press, New York, 1996, Fig. 3.6, p. 47.
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Reinforcements
Types of fiber fabric:
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Reinforcements
Typical cost of woven fabric
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Reinforcements
Mechanical properties common reinforcement materials
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Reinforcements
Mechanical properties common epoxy PMC materials reinforced with
carbon, aramid and glass fibers
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Reinforcements
Mechanical properties common reinforcement materials
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Reinforcements
: quasi‐isotropic
l: bulk
: unidirectional
S
Specific
ifi tensile
t il strength
t th and
d tensile
t il modulus
d l for
f different
diff t fibers
fib in
i an epoxy matrix
ti
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
Laminated Composites
LAMINATED COMPOSITES
Laminar composite
p example:
p continuous and alignedg fiber reinforced p
plastics
with matrixes such as epoxy, polyester, PE, PA, PET…
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
LAMINATED COMPOSITES
Laminated composites
p must always
y
be symmetric with respect to their
middle plane, and the must also be
balanced to avoid anomalous
distortions in the structure
str ct re
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials50
I
Topic 10: Composite Materials
SANDWICH COMPOSITES
2 external strong layers (face sheets) attached to a layer of less dense material
(core) with low stiffness and low strength
Role of the face sheets they withstand most of the plane loads and transversal bending
stresses
Face sheet material Al alloys, fiber-reinforced plastics, Ti, steel and plywood.
Core material separates both face sheets and resists deformations perpendicular to the
face plane. Provide resistance to shear stress along the planes perpendicular to the face
sheets
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
FIBER-METAL LAMINATES
GLARE
Although GLARE is a composite material, and manufacturing properties are comparable to
laminate aluminum alloy products, especially in the regard to aspects related to the design,
manufacture,
f t inspection
i ti or maintenance.
i t The
Th GLARE components t manufactured
f t d are built
b ilt and
d
repaired using mainly techniques typical of metallic materials.
The main advantages over conventional aluminum alloys are:
• improved damage tolerance (especially to impact and fatigue)
• better corrosion resistance
• better fire resistance
• lower density.
Airbus A380
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I