COMPOSITE MATERIALS

WHY COMPOSITES?
ADVANTAGES OVER TRADITIONAL
MATERIALS
CORROSION RESISTANCE
HIGH STRENGTH TO WEIGHT RATIO
LOW MAINTENANCE
EXTENDED SERVICE LIFE
DESIGN FLEXIBILITY

COMPOSITES DEFINITION
A combination of two or more materials (reinforcement,
resin, filler, etc.), differing in form or composition on a
macroscale. The constituents retain their identities, i.e..,
they do not dissolve or merge into each other, although they
act in concert. Normally, the components can be physically
identified and exhibit an interface between each other.
A judicious combination of two or more materials that
produces a synergistic effect. A material system composed
of two or more physically distinct phases whose
combination produces aggregate properties that are different
from those of its constituents

Composition / Phase
A composite material consists of two phases:
Primary
Forms the matrix within which the secondary phase is
imbedded
Any of three basic material types: polymers, metals, or
ceramics
Secondary
Referred to as the imbedded phase or called the
reinforcing agent
Serves to strengthen the composite. (fibers, particles,
etc.)
Can be one of the three basic materials or an element
such as carbon or boron

Classification of composite material

Metal Matrix Composites (MMCs)
Include mixtures of ceramics and metals, such as cemented
carbides and other cermets, as well as aluminum or magnesium
reinforced by strong, high stiffness fibers
Ceramic Matrix Composites (CMCs)
Least common composite matrix. Aluminum oxide and silicon
carbide are materials that can be imbedded with fibers for
improved properties, especially in high temperature applications
Polymer Matrix Composites (PMCs)
Thermosetting resins are the most widely used polymers in
PMCs. Epoxy and polyester are commonly mixed with fiber
reinforcement

METAL MATRIX COMPOSITES

Matrix material serves several functions in the
composite
provides the bulk form of the part or product
holds the imbedded phase in place
shares the load with the secondary phase

METAL MATRIX COMPOSITES

Common reinforcing phase includes
Particles of ceramic (commonly called cermets)
Fibers of various materials, including other metals,
ceramics, carbon, and boron
FRMMC combine the high tensile strength and
modulus of elasticity of a fiber with metals of low
density, thus achieving good strength-to-weight and
modulus-to-weight ratios in the resulting composite
material.

METAL MATRIX COMPOSITES

Cemented carbides are composed of one or more
Carbide compounds bonded in a metallic matrix
Common cemented carbides are based on:
Tungsten carbide (WC)
Titanium carbide (TiC)
Chromium carbide (Cr3C2)
Tantalum carbide (TaC)

METAL MATRIX COMPOSITES

Carbide ceramics constitute the principal ingredient in
cemented carbides, typically ranging in content from
80% to 95% of total weight.
Principle metallic binders are:
Cobalt used for WC
Nickel - used TiC and Cr3C2

METAL MATRIX COMPOSITES

Cutting tools are the most common application of
cemented carbides based on tungsten carbide
Titanium carbide cermets are used principally for high
temperature applications.
Nickel is the preferred binder; its oxidation resistance
at high temperature is superior to that of cobalt.
Used as a cutting tool material for machining steels.

CERAMIC MATRIX COMPOSITES

Advantage
High stiffness
Hardness
Hot hardness
Compressive strength
Relatively low density

Disadvantage
Low toughness and bulk
tensile strength
Susceptibility to thermal
cracking

Ceramic matrix composites represent an attempt to retain

the desirable properties of ceramics while compensating for
their weakness.

CERAMIC MATRIX COMPOSITES

Ceramic materials used as matrices includes:
Alumina
Boron carbide
Boron nitride
Silicon carbide
Silicon nitride
Titanium carbide

POLYMER MATRIX COMPOSITES

Fiber Reinforced Polymer (FRP) Composites
are defined as:
A matrix of polymeric material that is
reinforced by fibers or other reinforcing
material

COMPOSITES MARKETS

TRANSPORTATION
CONSTRUCTION
MARINE
CORROSION-RESISTANT
CONSUMER
ELECTRICAL/ELECTRONIC
APPLIANCES/BUSINESS
AIRCRAFT/DEFENSE

Infrastructure Benefits

HIGH STRENGTH/WEIGHT RATIO

ORIENTATED STRENGTH
DESIGN FLEXIBILITY
LIGHTWEIGHT
CORROSION RESISTANCE
LOW MAINTENANCE/LONG-TERM DURABILITY
LARGE PART SIZE POSSIBLE
TAILORED AESTHETIC APPEARANCE
DIMENSIONAL STABILITY
LOW THERMAL CONDUCTIVITY
LOW INSTALLED COSTS

FRP COMPOSITE
CONSTITUENTS
RESINS (POLYMERS)
REINFORCEMENTS
FILLERS
ADDITIVES

MATERIALS: RESINS
PRIMARY FUNCTION:
TO TRANSFER STRESS BETWEEN REINFORCING
FIBERS AND TO PROTECT THEM FROM
MECHANICAL AND ENVIRONMENTAL DAMAGE
TYPES:
THERMOSET
THERMOPLASTIC

RESINS
THERMOSET
POLYESTER
VINYL ESTER
EPOXY
PHENOLIC
POLYURETHANE

RESINS
THERMOPLASTIC
ACETAL
ACRYRONITRILE BUTADIENE STYRENE (ABS)
NYLON
POLYETHYLENE (PE)
POLYPROPYLENE (PP)
POLYETHYLENE TEREPHTHALATE (PET)

RESINS
THERMOSET ADVANTAGES
THERMAL STABILITY
CHEMICAL RESISTANCE
REDUCED CREEP AND STRESS RELAXATION
LOW VISCOSITY- EXCELLENT FOR FIBER
ORIENTATION
COMMON MATERIAL WITH FABRICATORS

RESINS
THERMOPLASTIC ADVANTAGES
ROOM TEMPERATURE MATERIAL STORAGE
RAPID, LOW COST FORMING
REFORMABLE
FORMING PRESSURES AND TEMPERATURES

POLYESTERS

LOW COST
EXTREME PROCESSING VERSATILITY
LONG HISTORY OF PERFORMANCE
MAJOR USES:
Transportation
Construction
Marine

VINYL ESTER
SIMILAR TO POLYESTER
EXCELLENT MECHANICAL & FATIGUE
PROPERTIES
EXCELLENT CHEMICAL RESISTANCE
MAJOR USES:
Corrosion Applications - Pipes, Tanks, & Ducts

EPOXY

EXCELLENT MECHANICAL PROPERTIES

GOOD FATIGUE RESISTANCE
LOW SHRINKAGE
GOOD HEAT AND CHEMICAL RESISTANCE
MAJOR USES:
FRP Strengthening Systems
FRP Rebars
FRP Stay-in-Place Forms

PHENOLICS

EXCELLENT FIRE RETARDANCE

LOW SMOKE & TOXICITY EMISSIONS
HIGH STRENGTH AT HIGH TEMPERATURES
MAJOR USES:
Mass Transit - Fire Resistance & High
Temperature
Ducting

POLYURETHANE
TOUGH
GOOD IMPACT RESISTANCE
GOOD SURFACE QUALITY
MAJOR USES:
Bumper Beams, Automotive Panels

SUMMARY: POLYMERS
WIDE VARIETY AVAILABLE
SELECTION BASED ON:
PHYSICAL AND MECHANICAL PROPERTIES
OF PRODUCT
FABRICATION PROCESS REQUIREMENTS

MATERIAL: FIBER
REINFORCEMENTS
PRIMARY FUNCTION:
CARRY LOAD ALONG THE LENGTH OF THE
FIBER, PROVIDES STRENGTH AND OR STIFFNESS
IN ONE DIRECTION
CAN BE ORIENTED TO PROVIDE PROPERTIES IN
DIRECTIONS OF PRIMARY LOADS

REINFORCEMENTS
NATURAL
MAN-MADE
MANY VARIETIES COMMERCIALLY AVAILABLE

MAN-MADE FIBERS

ARAMID
BORON
CARBON/GRAPHITE
GLASS
NYLON
POLYESTER
POLYETHYLENE
POLYPROPYLENE

FIBER PROPERTIES
DENSITY (g/cm3)
Steel

Alum

2.76

E-Glass

1.99

S-Glass

1.99

Carbon

1.59

Aramid

1.38
0

10

FIBER REINFORCEMENT
GLASS (E-GLASS)
MOST COMMON FIBER USED
HIGH STRENGTH
GOOD WATER RESISTANCE
GOOD ELECTRIC INSULATING PROPERTIES
LOW STIFFNESS

FIBER REINFORCEMENT
ARAMID (KEVLAR)
SUPERIOR RESISTANCE TO DAMAGE
(ENERGY ABSORBER)
GOOD IN TENSION APPLICATIONS (CABLES,
TENDONS)
MODERATE STIFFNESS
MORE EXPENSIVE THAN GLASS

FIBER REINFORCEMENT
CARBON
GOOD MODULUS AT HIGH TEMPERATURES
EXCELLENT STIFFNESS
MORE EXPENSIVE THAN GLASS
BRITTLE
LOW ELECTRIC INSULATING PROPERTIES

FIBER ORIENTATION
ANISOTROPIC
UNIDIRECTIONAL
BIAS - TAILORED DIRECTION
0O - flexural strengthening
90O - column wraps
+ /- 45O - shear strengthening
ANGLE VARIES BY APPLICATION

REINFORCEMENTS
SUMMARY
TAILORING MECHANICAL PROPERTIES
TYPE OF FIBER
PERCENTAGE OF FIBER
ORIENTATION OF FIBER

DESIGN VARIABLES
FOR COMPOSITES
TYPE OF FIBER
PERCENTAGE OF FIBER or FIBER VOLUME
ORIENTATION OF FIBER
0o, 90o, +45o, -45o

TYPE OF POLYMER (RESIN)

COST
VOLUME OF PRODUCT - MANUFACTURING
METHOD

DESIGN VARIABLES
FOR COMPOSITES
PHYSICAL:
tensile strength
compression strength
stiffness
weight, etc.
ENVIRONMENTAL:
Fire
UV
Corrosion Resistance

TAILORING COMPOSITE
PROPERTIES
MAJOR FEATURE
PLACE MATERIALS WHERE NEEDED - ORIENTED
STRENGTH
LONGITUDINAL
TRANSVERSE
or between
STRENGTH
STIFFNESS
FIRE RETARDANCY

MANUFACTURING
PROCESSES

Hand Lay-up/Spray-up
Resin Transfer Molding (RTM)
Compression Molding
Injection Molding
Reinforced Reaction Injection Molding (RRIM)
Pultrusion
Filament Winding
Vacuum Assisted RTM (Va-RTM)
Centrifugal Casting

PROCESS CHARACTERISTICS
Hand Lay-up/Spray-up

MAX SIZE:
PART GEOMETRY:
PRODUCTION VOLUME:
CYCLE TIME:
SURFACE FINISH:
TOOLING COST:
EQUIPMENT COST:

Unlimited
Simple - Complex
Low - Med
Slow
Good - Excellent
Low
Low

PRODUCT CHARACTERISTICS
Pultrusion

CONSTANT CROSS SECTION

CONTINUOUS LENGTH
HIGH ORIENTED STRENGTHS
COMPLEX PROFILES POSSIBLE
HYBRID REINFORCEMENTS

MATERIAL PROPERTIES
PROPERTIES OF FRP COMPOSITES VARY
DEPENDING ON:
TYPE OF FIBER & RESIN SELECTED
FIBER CONTENT
FIBER ORIENTATION
MANUFACTURING PROCESS

REPAIR
HYBRIDS (SUPER COMPOSITES): TRADITIONAL
MATERIALS ARE JOINED WITH FRP
COMPOSITES
WOOD
STEEL
CONCRETE
ALUMINUM

BENEFITS - SUMMARY

LIGHT WEIGHT
HIGH STRENGTH to WEIGHT RATIO
COMPLEX PART GEOMETRY
COMPOUND SURFACE SHAPE
PARTS CONSOLIDATION
DESIGN FLEXIBILITY
LOW SPECIFIC GRAVITY
LOW THERMAL CONDUCTIVITY
HIGH DIELECTRIC STRENGTH

STRUCTURAL DESIGN WITH

FRP COMPOSITES