Lecture 01

Introduction to Manufacturing
of Composites

Dr. J. Ramkumar
Professor
Dept of Mechanical & Design Program
IIT Kanpur
Contents
 Concept of composites
 Classification of composites
 Metals vs composites
 Special features of composites
 Applications of composites
 Monomers and polymers
 Polymerization mechanisms
The concept of composites
 In the broad sense, the term composite materials refers to all
solid materials composed of more than one component,
wherein those components are in separate phases.
Classification of composites -based on
dispersed phase

Balasubramanian, M., 2013. Composite materials and processing. CRC press.

Classification of composites -based on
matrix material

Balasubramanian, M., 2013. Composite materials and processing. CRC press.

Property comparison:
metals vs composites.

Strong, A.B., 2008. Fundamentals of composites manufacturing:

materials, methods and applications. Society of Manufacturing Engineers.
Special Features of Composites
1. Composite materials have a high specific stiffness (stiffness-
to-density ratio). Composites offer the stiffness of steel at
one fifth the weight and equal the stiffness of aluminum at
one half the weight.
2. The specific strength (strength-to-density ratio) of a
composite material is very high. Due to this, airplanes and
automobiles move faster and with better fuel efficiency. The
specific strength is typically in the range of 3 to 5 times that
of steel and aluminum alloys.
3. Net-shape or near-net-shape parts can be produced with
composite materials. This feature eliminates several
machining operations and thus reduces process cycle time
and cost.
Special Features of Composites
4. Composite materials provide capabilities for part integration.
Several metallic components can be replaced by a single
composite component.
5. Composite structures provide in-service monitoring or online
process monitoring with the help of embedded sensors
Materials known as “smart” materials.
Composites applications

http://www.buykorea.org/product-details/composite-autoclave--70768.html
Composites applications

https://www.linkedin.com/pulse/difference-between-carbon-fiber-glass-shao-liya
Composites applications

http://aerospace.eng.usm.my/mohdshukur/index.php/subjects
Composites applications

http://aerospace.eng.usm.my/mohdshukur/index.php/subjects
Composites applications

http://www.compositepanelsystems.com/
Composites applications

http://www.nanowerk.com/spotlight/spotid=23934.php
Composites applications

http://www.airexbaltekbanova.com/market-solutions/marine.html
 Composites applications

Many defence applications now rely on unique properties

delivered by modern composite materials. PRF develops,
manufactures and supplies composites that support defence
application

http://www.prfcomposites.com/wp-content/uploads/2012/10/iStock_000014839443XLarge.jpg
https://www.pinterest.com/pin/554294666607846427/
http://compositesmanufacturingmagazine.com/2011/03/defense-applications-trending-towards-composites/
Composites applications

http://www.azom.com/article.aspx?ArticleID=12194
http://www.qmed.com/mpmn/medtechpulse/readying-medical-device-
composite-materials-takeoff
http://www.e-xstream.com/industries/medical-devices
https://www.uweb.engr.washington.edu/research/tutorials/introbiomat.html
Specific strength and stiffness values
-conventional materials and composites

Balasubramanian, M., 2013. Composite materials and processing. CRC press.

Polymers, plastics and resins
 Matrix materials can be polymeric, metallic, or ceramic.
 The terms plastics and resins are often used to refer to
polymer matrices
 The term polymer means “many units” and refers to
the way in which individual molecular units are joined
together into a chain-like structure where each unit is
like a link in the chain.
 Monomers uniting to form a
polymer

A monomer:
• Monomers - single molecular unit that can be made into a polymer. They are made of atoms and
have a specific and consistent grouping.

A polymer molecule:
• Several monomers linked together into a polymer chain - a single long chain.
• They are found as mixtures of many similar chains clustered in a group.

Strong, A.B., 2008. Fundamentals of composites manufacturing:

materials, methods and applications. Society of Manufacturing Engineers.
Addition polymerization

The process of synthesizing addition polymers is known as addition polymerization. There

should be multiple bonded monomers to initiate such reaction. This is a chain reaction;
therefore, any number of monomers can join into a polymer. There are three steps to a
chain reaction, they are initiation, propagation and termination.

Strong, A.B., 2008. Fundamentals of composites manufacturing:

materials, methods and applications. Society of Manufacturing Engineers.
Condensation polymerization

Any condensation process, which results in the formation

of polymers, is known as condensation polymerization. The
monomer should have functional groups in ends, which can
react together to continue the polymerization.
Strong, A.B., 2008. Fundamentals of composites manufacturing:
materials, methods and applications. Society of Manufacturing Engineers.
Assignment 1

Choose a product made of composites, and

compare the same with the earliar version
made out of conventional material.
List down the benefits as a customer.