 An Introduction to

Composites

List of materials we know
 What is a Composite?
• A combination of two or more
different materials
– Properties are superior to that of
individual materials

Metals
 Concrete

Plastics Ceramics
CFRP, GFRP
 What is a Composite

Matrix Composite Reinforcemen

t

Epoxy Glass
Polyamides Carbon
Polyester Thermoplastic
Silicone fibres
Metals
Steel Ceramics
Aluminium Tungsten carbide

boron nitride
Carbon fibre
• Why a bunch of ceramic fibres are
stronger than the Bulk material?
 Reinforcements
• Glass fibre
• Carbon fibre
• Boron fibre
• Thermoplastic fibres
• Metal
– Wire, powder
• Ceramics
– SiC, Al2O3


Reinforcement Schemes


• Continuous fibre (or yarn)

– UD laminates
– Fibre Woven
• Chopped fibre/ whiskers
• Flakes
• Skeletal
– Honeycomb
• Glass fibre
– Most commonly used
– Produced by extrusion
– E-Glass – electrical applications
– S-Glass – High strength applications
• Boron fibre
– Produced by Chemical Vapour Deposition
– Higher tensile modulus
– High cost
– Aerospace/ military applications
 Prepregs
• reinforcement material pre-impregnated
with a resin matrix in controlled quantities
• The resin is partially cured (called B-state)
• fabricator lays up the finished part and
completes the cure with heat and
pressure


– Low void content

– Control of fibre volume fraction
– Control of laminate thickness
– Labour cost lower
– Better quality and conformity
 Fabrication methods
• Vacuum Bag Moulding
• Autoclave Moulding
• Press Moulding
• Pressure Bag Moulding
• Filament Winding
• Thermal Expansion Moulding
• Pultrusion
 A widely Used Example


 CFRP


 Carbon Fibre Reinforced Plastics

 (Carbon-epoxy composites)
CFRP
– CFRP piece consists:
• 50-70% of woven Carbon fibre
• 10-25% of Epoxy Resin
• 8-28% of Polyamines
 Carbon Fibre-How its made


• Carbon Fibre production by Pyrolyzing

Oxidising Carbonising Graphitising

200 - 300℃ 1500 - 2000℃ 2500 - 3000℃

PAN (55%)
Rayon

High
Pitch(85%) Modulus
High Carbon
 Strength
Carbon


–
–
–
 Epoxy-matrix material
• Used as a Coating, adhesive, insulator
• Dulux® Epoxy floor paint (heavy duty)
• Epoxide/polyamine
(Resin/Hardener)
  Ex.:
• Ethylene Oxide
• Propylene Oxide
•
• The matrices most widely used for
composites in commercial and high-
performance aerospace applications
are thermoset resins, consisting of
polymer chains that are permanently
 Epoxies
• Highest strength/ stiffness
• Low viscosity for wetting
• Low shrinkage
•


• What is Stiffness?
 CFRP-Properties
• Can be Engineered to
Suite the application
Specific Tensile
–
Carbon Density
1.8 Strength
1.10 (for
– add directional
Fibre
Epoxy 1.2 CFRP)
strength
Aluminiu 2.7 0.23 – high service
m High tensile strength/ temperature
weight
 Very stiff – impact resistance
 low thermal expansion – improved hot/wet
mechanical
 environmental
performance
resistance
– fire retardancy
 – Complex shapes
– Can be automated
 CFRP-Advantages
• Due to the high specific modulus and strength of the
materials, very strong and stiff structures can be
designed, with substantial weight savings.
• The ability to align the fibre orientation with the direction of
principle stresses and, therefore, achieve high structural
efficiency.
• Exceptional environmental degradation and corrosion
resistance properties.
• Very low coefficient of thermal expansion, with the added
possibility of designing the material to give desired
thermal expansion in a particular direction.
• Improved vibration damping properties.
• Easy repairability of damaged structures.
• Ability to manufacture complex shapes at lower costs
compared with fabricated or machined metallic alloys.
• Time and cost reductions on tooling and manufacturing of
one-offs, prototypes and short length production runs.
• Excellent fatigue life, i.e. carbon fibre composites can be
designed to be essentially fatigue free.
• Improved energy absorbing safety structures.
 Industry Applications
• Aerospace
– Structural components, aircraft flooring, aircraft
prototypes, unmanned air vehicles (UAVs), space
structures, missile components
• Motorsport
– Bodywork & structural components, engine covers,
– underbodies, heat shields, impact structures,
prototypes
• Marine
– Hulls, decks, covers
• Sports
– Bicycles, skis/snowboards, helmets, tennis racquets,
kayaks, fishing rods, golf clubs
• Automotive
– Prototype panels, combination/checking fixtures,
sports/niche car components, interior trims,
springs, drive shafts, exhausts
• Others
Boeing 787 - Dreamliner
 Boeing 787 Dreamliner
•
Ø Largest & most critical application to rely on CFRP
• Close to100% of skin
• 50% of all material of the plane
• 80% lesser number of drill-holes/rivets
• 20% saving on fuel consumption
• corrosion and fatigue benefits - remain
in service for 12 years before its first
structural test
• assemble each 787 in just three days,
down from 11 days for the 737
 Some Drawbacks
• Expensive
• Non-homogeniety/ discontinuity
• Difficult to machine
– Delamination
– Potentially toxic dust formation
– Fibre pull-outs
– Tool wear
• Disposal can be expensive and
environmentally hazardous
• Recycling is costly and may not give the
same strength

Important websites
• www.toray.com
• www.compositesworld.com
• www.mmsonline.com
• www.wikipedia.org
• www.boeing.com
• www.riversimple.com
•
•
•
 Refferences
• Kenneth G. Budinski, Michael K.
Budinski; Engineering Materials –
Properties and Selection; Sixth
Edition; Prentice Hall, 1999, pp125


Thank You


Any Questions?
