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Chapter 15: Composites

Many engineering components are composites

Chapter 15: Composites

ISSUES TO ADDRESS...
What are the classes and types of composites? Why are composites used instead of metals, ceramics, or polymers? How do we estimate composite stiffness & strength? What are some typical applications?

MSE 280: Introduction to Engineering Materials

D.D. Johnson 2004, 2006-2008

MSE 280: Introduction to Engineering Materials

D.D. Johnson 2004, 2006-2008

Classification of Composites
Composites: Matrix:
- Multiphase material w/significant proportions of ea. phase.

COMPOSITE SURVEY: Particle-I


Particle-reinforced Examples:
Adapted from Fig. 10.10, Callister 6e.

- The continuous phase - Purpose is to:


transfer stress to other phases protect phases from environment

- Classification: MMC, CMC, PMC metal ceramic polymer


From D. Hull and T.W. Clyne, An Intro to Composite Materials , 2nd ed., Cambridge University Press, New York, 1996, Fig. 3.6, p. 47. Adapted from Fig. 16.4, Callister 6e.

Dispersed phase:
-Purpose: enhance matrix properties.
MMC: increase s y, TS, creep resist. CMC: increase Kc PMC: increase E, s y, TS, creep resist.

Adapted from Fig. 16.5, Callister 6e.

-Classification: Particle, fiber, structural


MSE 280: Introduction to Engineering Materials
D.D. Johnson 2004, 2006-2008

MSE 280: Introduction to Engineering Materials

D.D. Johnson 2004, 2006-2008

COMPOSITE SURVEY: Particle-II


Particle-reinforced

COMPOSITE SURVEY: Fiber-I


Particle-reinforced
Fiber-reinforced

Elastic modulus, Ec, of composites:


-- two approaches.

Structural

Aligned Continuous fibers Ex: --Metal: g'(Ni3Al)-a(Mo)


by eutectic solidification.

--Glass w/SiC fibers


formed by glass slurry E glass = 76GPa; E SiC = 400GPa.

(a)
Fig. 15.3
From F.L. Matthews and R.L. Rawlings, Composite Materials; Engineering and Science , Reprint ed., CRC Press, Boca Raton, FL, 2000. (a) Fig. 4.22, p. 145 (photo by J. Davies); (b) Fig. 11.20, p. 349 (micrograph by H.S. Kim, P.S. Rodgers, and R.D. Rawlings).

Application to other properties:


-- Electrical conductivity, s e: Replace E by s e. -- Thermal conductivity, k: Replace E by k.
MSE 280: Introduction to Engineering Materials
D.D. Johnson 2004, 2006-2008

(b)
From W. Funk and E. Blank, Creep deformation of Ni3Al-Mo in-situ composites", Metall. Trans. A Vol. 19(4), pp. 987-998, 1988.

MSE 280: Introduction to Engineering Materials

D.D. Johnson 2004, 2006-2008

COMPOSITE SURVEY: Fiber-II


Particle-reinforced Fiber-reinforced Discontinuous, random 2D fibers Example: Carbon-Carbon
--process: fiber/pitch, then burn out at up to 2500C. --uses: disk brakes, gas turbine exhaust flaps, nose cones.
(b)

Elasticity of Composites
Stress-strain response depends on properties of reinforcing and matrix materials (carbon, polymer, metal, ceramic) volume fractions of reinforcing and matrix materials orientation of fibre reinforcement (golf club, kevlar jacket) size and dispersion of particle reinforcement (concrete) absolute length of fibres, etc.

Structural

C fibers: very stiff very strong C matrix: less stiff view onto plane less strong fibers lie in plane

concentration

size

shape

(a)

Other variations:
--Discontinuous, random 3D --Discontinuous, 1D

distribution

orientation

MSE 280: Introduction to Engineering Materials

D.D. Johnson 2004, 2006-2008

MSE 280: Introduction to Engineering Materials

D.D. Johnson 2004, 2006-2008

Families of Composites: particle, fibre, structural reinforcements

Two simplest cases: Iso-load and Iso-strain


Isostrain: Load & Reinforcements Aligned F Strain or elongation of matrix and fibers are the same!

V % V = VTot
Volume fraction

% Ec = =1, N E V
F

ceramics

Twisting, Bending Orientation dependence

Isoload: Load & Reinforcements Perpendicular (Isostress below) F Load (Stress) across matrix and fibers is the same!

% 1 V = =1, N Ec E
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F
MSE 280: Introduction to Engineering Materials
D.D. Johnson 2004, 2006-2008

MSE 280: Introduction to Engineering Materials

D.D. Johnson 2004, 2006-2008

10

Isostrain Case in Ideal Composites


Isostrain Case: strain forces

Iso-Load Case for Ideal Composites


Isoload Case: strain forces

c = m = r

c = m + r

Fc = Fm + Fr
*if the fibers are continuous, then volume fraction is easy.

Fc = Fm = Fr

F
Without de-bonding, loads are equal, therefore, strains must add, so
% % % % elastic case c = mVm + f V f = Vm + V f *if the fibers are continuous or planar, then area of applied Em Ef
stress is the same.

Load is distributed over matrix and fibers, so cA c = mAm + fAf.

c = m (Am / Ac ) + f (A f / Ac ) % % or c = mVm + f V f

% % % % For Elastic case: c = c Ec = m EmVm + f E f V f = c (EmVm + E f V f )


Composite Property:

% Pc = =1, N P V

* like law of mixtures

Composite Property:

% 1 V = =1, N Pc P

* like resistors in parallel.

Properties include: elastic moduli, density, heat capacity, thermal expansion, specific heat, ...
MSE 280: Introduction to Engineering Materials
D.D. Johnson 2004, 2006-2008

Properties include: elastic moduli, density, heat capacity, thermal expansion, specific heat, ...
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MSE 280: Introduction to Engineering Materials
D.D. Johnson 2004, 2006-2008

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ISOSTRAIN Example Suppose a polymer matrix (E= 2.5 GPa) has 33% fibre reinforcements of glass (E = 76 GPa). What is Elastic Modulus?

ISOLOAD Example Suppose a polymer matrix (E= 2.5 GPa) has 33% fibre reinforcements of glass (E = 76 GPa). What is Elastic Modulus? Rearrange:

Ec = VmE m + Vf E f =(1 Vf )Em + Vf Ef Vf Ef


= 26.7 GPA ~ 25 GPA

1 = Vm + Vf Ec Em Ef
Em (1 Vf )
= 3.8 GPA

E=
C

Vf E m + (1 Vf )E f

EmEf

* Stiffness of composite under isostrain is dominated by fibers.

* Elastic modulus of composite under isoload condition strongly depends on stiffness of matrix, unlike isostrain case where stiffness dominates from fibers.
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MSE 280: Introduction to Engineering Materials

MSE 280: Introduction to Engineering Materials

D.D. Johnson 2004, 2006-2008

D.D. Johnson 2004, 2006-2008

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Modulus of Elasticity in Tungsten Particle Reinforced Copper

Simplified Examples of Composites

isostrain

isoload

Are these isostrain or isoload? What are some real life examples?

Particle reinforcements usually fall in between two extremes.


MSE 280: Introduction to Engineering Materials
D.D. Johnson 2004, 2006-2008

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MSE 280: Introduction to Engineering Materials

D.D. Johnson 2004, 2006-2008

16

Simplified Examples of Composites


A
Load, F Material A and B are different e.g., walkway, trapeze bar,

200,000 unloading

Self-Assessment Example: isostrain


A B
A platform is suspended by two parallel rods (A and B). Yielding of either rod of this composite constitutes failure, such as the falling (and possible death) of the trapeze artist, the people using the walkway, etc.
Each rod is 1.28 cm in diameter. Rod A is 4340 steel, with E= 210 GPa, ys = 855 MPa. Rod B is 7075-T6 Al alloy, with E= 70 GPa, ys = 505 MPa.

||
Load, F Fiber reinforced epoxy cylinder e.g, pressure cylinder

(a) What uniform load can be applied to the platform before yielding will occur? If not elastic, then composite fails, due to permanent deformation! Hence
A = A ys EA
=

3" 4" 6"

B F A F

B 855MPa ys 505MPa = 4.07x 103 B = = = 7.21x 103 210GPa EB 70GPa

C A < B

F = FA + FB = Arod ( A + B ) = Arod (E AA + EB B ) = Arod rod (E A + EB )

F=
(1.28x 102 m )2 (4.07x 103 )(210 + 70)GPa = 146.6kN 4

60,000 permanent strain.

(b) Which rod will be first to yield? Justify and explain your answer.

welded tubular composite


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C A < B

Steel yieldsfirst! To justify, consider how much load is carried F A/F B


relative to that expected from the YS. 18

MSE 280: Introduction to Engineering Materials

D.D. Johnson 2004, 2006-2008

MSE 280: Introduction to Engineering Materials

D.D. Johnson 2004, 2006-2008

COMPOSITE SURVEY: Fiber-III


Particle-reinforced
fiber strength in tension

COMPOSITE SURVEY: Fiber-IV


Particle-reinforced
Fiber-reinforced

Fiber-reinforced

Structural

Structural

Critical fiber length for effective stiffening & strengthening:


d fiber length > 15 f c
fiber diameter shear strength of fiber-matrix interface

Estimate of Ec and TS:

d --valid when fiber length > 15 f c

-- Elastic modulus in fiber direction:

Ex: For fiberglass, fiber length > 15mm needed Why? Longer fibers carry stress more efficiently!
Shorter, thicker fiber: d fiber length < 15 f

Ec = EmVm + KEfVf
efficiency factor:
--aligned 1D: K = 1 (anisotropic) --random 2D: K = 3/8 (2D isotropy) --random 3D: K = 1/5 (3D isotropy)
Values from Table 15.3

Longer, thinner fiber: d fiber length > 15 f

--TS in fiber direction:

Adapted from Fig.15.7

(TS)c = (TS)mVm + (TS)f Vf


Better fiber efficiency
D.D. Johnson 2004, 2006-2008

(aligned 1D)

Poorer fiber efficiency


MSE 280: Introduction to Engineering Materials

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MSE 280: Introduction to Engineering Materials

D.D. Johnson 2004, 2006-2008

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COMPOSITE SURVEY: Structural


Structural

Composite Benefits
CMCs: Increased toughness PMCs: Increased E/r

Stacked and bonded fiber-reinforced sheets


-- stacking sequence: e.g., 0/90 -- benefit: balanced, in-plane stiffness
Fig. 15.16

Sandwich panels
-- low density, honeycomb core -- benefit: small weight, large bending stiffness

MMCs:
Increased creep resistance
Fig. 15.17

Adapted from T.G. Nieh, "Creep rupture of a silicon-carbide reinforced aluminum composite", Metall. Trans. A Vol. 15(1), pp. 139-146, 1984.

MSE 280: Introduction to Engineering Materials

D.D. Johnson 2004, 2006-2008

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MSE 280: Introduction to Engineering Materials

D.D. Johnson 2004, 2006-2008

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Laminate Composite (Ideal) Example


Gluing together these composite layers composed of epoxy matrix (E m= 5 GPa) with graphite fibres (Ef= 490 GPa and Vf = 0.3). Central layer is oriented 90 0 from other two layers. Case I - Load is applied parallel to fibres in outer two sheets. Case II - Load is applied parallel to fibres of central sheet. What are effective elastic moduli in the two case? First need to know how individual sheets respond, then average.
1 0.3 0.7 = + E = 7.1 GPa E 490 GPa 5 GPa E|| = 0.3(490 GPa) + 0.7(5 GPa) E|| = 150.5 GPa

Mechanical Response of Laminate: Complex, NOT Ideal 3 Conditions required: consider top and bottom before laminated
strain compatibility- top and bottom must have same strain when glued. stress-strain relations - need Hookes Law and Poisson effect. equilibrium - forces and torques, or twisting and bending.
Isostrain for load along x-dir: Poisson Effect and Displacements in D:

top =
x

For isoload case. For isotrain case.

top bott x E bott E top = top bott y y E bott

Case I: E lam =(2/3)(150.5 GPa) + (1/3)(7.1 GPa) = 102.7 GPa Case II: E lam =(1/3)(150.5 GPa) + (2/3)(7.1 GPa) = 54.9 GPa
MSE 280: Introduction to Engineering Materials
D.D. Johnson 2004, 2006-2008

When glued together displacements have to be same! Unequal displacements not allowed! So, top gets wider (ytop > 0) and bottom gets narrower ( ybott < 0). Equilibrium: Fy = 0 = (ybot t bot + ytop ttop)L. (t = thickness)
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MSE 280: Introduction to Engineering Materials

D.D. Johnson 2004, 2006-2008

COMPATIBILITY: When glued, displacements have to be same!

Symmetry of laminate composite dictates properties

As stress is applied, compatibility can be maintained, depending on the laminate, only if materials twists.
MSE 280: Introduction to Engineering Materials
D.D. Johnson 2004, 2006-2008

Elastic constants are different for different symmetry laminates.


MSE 280: Introduction to Engineering Materials
D.D. Johnson 2004, 2006-2008

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Orientation of layers dictates response to stresses

NO delamination - failure!

Want compressive stresses at end of laminate so there are no tensile stresses to cause delamination - failure!

Apply in-pane Tensile Stress A B +90 +45 +45 45 45 +90 45 +90 +45 45 +90 +45 Tensile -> delaminate Compressive
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MSE 280: Introduction to Engineering Materials

D.D. Johnson 2004, 2006-2008

MSE 280: Introduction to Engineering Materials

D.D. Johnson 2004, 2006-2008

Why Laminate Composite is NOT Ideal


Depending on placement of load and the orientation of fibers internal to sheet and the orientation of sheets relative to one another, the response is then very different. Examples of orientations of laminated sheets that provided compressive stresses at edges of composite and also tensile stresses there. >>>> Tensile stresses lead to delamination! The stacking of composite sheets and their angular orientation can be used to prevent twisting moments but allow bending moments. This is very useful for airplane wings, golf club shafts (to prevent slices or hooks), tennis rackets, etc., where power or lift comes or is not reduced from bending.

Thermal Stresses in Composites


Not just due to fabrication, rather also due to thermal expansion differences between matrix and reinforcements Tm and Tr. Thermal coatings, e.g. | m r | TE = T TEc T T
At T 1 At T 2
If forced to be compatible, composite will bend and rotate

Material with most contraction (least) has positive (negative) residual stress. (For non-ceramics, you should consider plastic strain too.) Ceramic-oxide thermal layers, e.g. on gas turbine engines: ceramic coating ZrO 2-based (lower Tr) metal blade (Ni xCo1-x )CrAlY (higher Tm) Failure by delamination without a good design of composite, i.e. compatibility maintained.

MSE 280: Introduction to Engineering Materials

D.D. Johnson 2004, 2006-2008

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MSE 280: Introduction to Engineering Materials

D.D. Johnson 2004, 2006-2008

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Summary
Composites are classified according to:
-- the matrix material (CMC, MMC, PMC) -- the reinforcement geometry (particles, fibers, layers).

Composites enhance matrix properties:


-- MMC: enhance s y, TS, creep performance -- CMC: enhance K c -- PMC: enhance E, s y, TS, creep performance Particulate-reinforced: -- Elastic modulus can be estimated. -- Properties are isotropic. Fiber-reinforced: -- Elastic modulus and TS can be estimated along fiber dir. -- Properties can be isotropic or anisotropic. Structural: -- Based on build-up of sandwiches in layered form.
MSE 280: Introduction to Engineering Materials
D.D. Johnson 2004, 2006-2008

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