Project On :

Fabrication of COMPOSITE MATERIAL

WHAT IS COMPOSITE MATERIAL?

Composite materials(also calledcomposition
materialsor shortened tocomposites) are materials
made from two or more constituent materials with
significantly differentphysicalorchemical properties,
that when combined, produce a material with
characteristics different from the individual components.

The individual components remain separate and distinct

within the finished structure.

Composite materials are generally used forbuildings,

bridges and structures such as boat hulls, swimming pool
panels, race car bodies , showerstalls,bathtubs and
storage tanks.

OVER VIEW
Composites are made up of individual materials referred
to as constituent materials.
There are two main categories of constituent materials:
matrix and reinforcement.
The matrix material surrounds and supports the
reinforcement materials by maintaining their relative
positions.
The reinforcements impart their special mechanical and
physical properties to enhance the matrix properties.
The matrix material can be introduced to the
reinforcement before or after the reinforcement material
is placed into themould cavity or onto the mould surface.

 The matrix material experiences a melding event, after

which the part shape is essentially set.
Depending upon the nature of the matrix material, this
melding event can occur in various ways such as
chemicalpolymerization or solidification from the
melted state.
Many commercially produced composites use
apolymermatrix material often called a resin solution.
There are many different polymers available depending
upon the starting raw ingredients.
The most common are known aspolyester,vinyl
ester,epoxy,phenolic,polyimide,polyamide,polypropyl
ene,PEEK, and others.

TYPES OF COMPOSITE
MATERIAL
Concreteis the most common artificial composite material of all .
Concrete is a very robust material, much more robust than cement,
and will not compress or shatter even under quite a large
compressive force. However, concrete cannot survive tensile
loading (i.e., if stretched it will quickly break apart).

Fibre-reinforced polymersor FRPs includecarbon-fiber-reinforced

polymeror CFRP, andglass-reinforced plasticor GRP.

If classified by matrix then there are thermoplastic

composites,short fibre thermoplastics,long fibre thermoplasticsor
long fibre-reinforced thermoplastics.

There are numerousthermosetcomposites, but advanced systems

usually incorporatearamidfibreand carbon fibre in anepoxy
resinmatrix.

 Composites can also use metal fibres reinforcing other

metals, as inmetal matrix composites(MMC) orceramic
matrix composites(CMC).
Additionally, thermoplastic composite materials can be
formulated with specific metal powders resulting in
materials with a density range from 2 g/cm to 11 g/cm
(same density as lead).
The most common name for this type of material is "high
gravity compound" (HGC), although "lead replacement" is
also used.
These materials can be used in place of traditional
materials such as aluminium, stainless steel, brass,
bronze, copper, lead, even tungsten in weighting and
balancing (for example, modifying the centre of gravity of
a tennis racquet)

PRODUCTS

Fiber-reinforced composite materials have gained popularity (despite their

generally high cost) in high-performance products that need to be light
such as weight of aerospace
components(tails,wings,fuselages,propellers),boat
andscullhulls,bicycle frames, swimming pool panels andracing car
bodies.

Other uses includefishing rods , storage tanks, swimming pool panels,

andbaseball bats.

The newBoeing 787structure including the wings and fuselage is

composed largely of composites.

Composite materials are also becoming more common in the realm

oforthopedic surgery .

Carbon composite is a key material in today's launch vehicles andheat

shields for there-entry phase ofspacecraft .

It is widely used in solar panel substrates, antenna reflectors and yokes of

WHY WE NEED COMPOSITES

MATERIAL ?

Design Flexibility -Thermoset Composites give designers nearly

unlimited flexibility in designing shapes and forms. They be
molded into the most intricate components and can be made a
wide range of densities and chemical formulations to have precise
performance properties.

Low cost per cubic inch-When comparing costs based on

volume, thermoset composites have lower material costs than
traditional materials such as wood, engineered thermoplastics and
metals. In addition, because thermoset composites have a low
petroleum-based content, they are not subjected to the price
fluctuations experienced in petroleum-based products.

Improved productivity Industrial Designers and Engineers are

able to reduce assembly costs by combining several previously
assembles parts into a single component. Also, inserts can be
molded directly into the part during the molding process thereby
eliminating the need for a post-process. In addition, composites do
not usually require additional machining, thereby reducing work-inprocess and time to market.

Lower material costs-Because thermoset composites can be

precisely molded, there is little waste and therefore significantly
lower overall material costs than metals products

Other key advantages include :

As molded dimensional accuracy

Tight tolerance, repeatable moldings
Low-post mold shrinkage
Corrosion Resistance
Design Flexibility
Durable
High Flexural Modulus to Carry Demanding Loads
High Impact Strength

High Performance at Elevated Temperatures

Heat Resistance
Naturally Flame Retardant
Creep Resistance
Mechanical Property Retention
Superior Thermal Stability

Lighter Weight than Metal

Low Petrochemical content

Better cost stability than commodities
Lower Cost per Cubic Inch as compared to Thermoplastics
Molded-in Color
Molded in inserts
Outstanding Electrical Insulation
a)
Arc and Track Resistance
b) Ability to Quench

PROJECT DESCRIPTION
Firstly, we will take the aluminium alloy.
Then we will test the alloy properties such as hardness, ultimate
tensile strength , compressive strength , impact strength and
grain structure.
Then to increase the mechanical properties we will make the
composite material by using ceramic reinforcement particles and
molten aluminium for metal matrix composite (MMC) production
by casting.
Then we will again test the properties of composite material such

Hardness
Ultimate tensile strength
Compressive strength
Impact strength
Grain structures etc.

THANK
YOU