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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?
Classification of Composites
Composites: Matrix:
- Multiphase material w/significant proportions of ea. phase.
Dispersed phase:
-Purpose: enhance matrix properties.
MMC: increase s y, TS, creep resist. CMC: increase Kc PMC: increase E, s y, TS, creep resist.
Structural
(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).
(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.
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
V % V = VTot
Volume fraction
% Ec = =1, N E V
F
ceramics
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
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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.
c = m (Am / Ac ) + f (A f / Ac ) % % or c = mVm + f V f
% Pc = =1, N P V
Composite Property:
% 1 V = =1, N Pc P
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:
1 = Vm + Vf Ec Em Ef
Em (1 Vf )
= 3.8 GPA
E=
C
Vf E m + (1 Vf )E f
EmEf
* 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
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isostrain
isoload
Are these isostrain or isoload? What are some real life examples?
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200,000 unloading
||
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
=
B F A F
C A < B
F=
(1.28x 102 m )2 (4.07x 103 )(210 + 70)GPa = 146.6kN 4
(b) Which rod will be first to yield? Justify and explain your answer.
C A < B
Fiber-reinforced
Structural
Structural
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
(aligned 1D)
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Composite Benefits
CMCs: Increased toughness PMCs: Increased E/r
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.
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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
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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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
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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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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.
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Summary
Composites are classified according to:
-- the matrix material (CMC, MMC, PMC) -- the reinforcement geometry (particles, fibers, layers).
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