Introduction to Composites

What are Composites?

Composites: 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.
Composites: Artificially produced multiphase materials.

Composites: Design materials with properties better than those

of conventional materials (metals, ceramics, or polymers).

Composites: materials, usually man-made, that are a three

dimensional combination of at least two chemically distinct
materials, with a distinct interface separating the components, created
to obtain properties that cannot be achieved by any of the
components acting alone.
Composites: are combinations of two materials in which one of the
materials, called the reinforcing phase, is in the form of fibers, sheets,
or particles, and is embedded in the other materials called the matrix
phase. The reinforcing material and the matrix material can be metal,
ceramic, or polymer

In their broadest form, composites are materials consist of two or

more constituents. The constituents are combined in such a way that
they keep their individual physical phases and are not soluble in
each other or not to form a new chemical compound.

One constituent is called reinforcing phase and the one in which the
reinforcing phase is embedded is called matrix.

 Historical or natural examples of composites are abundant: brick made

of clay reinforced with straw, mud wall withbamboo shoots, concrete,
concrete reinforced with steel rebar, granite consisting of quartz, mica
and feldspar, wood (cellulose fibers in lignin matrix), etc.
Advanced Composites: Advanced composite materials are refereed
to those composite materials developed and used in the aerospace
industries. They usually consist of high performance fibers as
reinforcing phases and polymers or metals as matrices.

Definition: An advanced composite material comprises at least

two chemically different materials (heterogeneity):
a reinforcement, and a matrix
that binds the reinforcement
and is separated from it by a sharp
interface.

Dispersed phase
within continuous phase
 Types of composites
(MMC, PMC, CMC)

We will focus on artificial Wood (cellulose fibers with stiffer lignin matrix)
composites. Bone (soft collagen and brittle apatite)
Natural composites include: Clay (particles and glass naturally form when fired)
 Phases of Composites
Matrix Phase: Polymers, Metals, Ceramics
Also, continuous phase, surrounds other phase (e.g.:
metal, ceramic, or polymer)

Reinforcement Phase: Fibers, Particles, or Flakes

Also, dispersed phase, discontinuous phase (e.g.:
metal, ceramic, or polymer)

→ Interface between matrix and reinforcement

Examples:
– Jello and cole slaw/mixed fruit
– Peanut brittle
– Straw in mud
– Wood (cellulose fibers in hemicellulose and lignin)
– Bones (soft protein collagen and hard apatite minerals)
– Pearlite (ferrite and cementite)
 Ceramics
Ceramics: Ceramic materials are inorganic, nonmetallic
materials. Most ceramics are compounds between metallic and
nonmetallic elements for which the inter atomic bonds are either
totally ionic or predominantly ionic but having some
covalent character.
The term ceramic comes from the Greek word keramikos,
which means burnt stuff, indicating that desirable properties
of these materials are normally achieved through a high
temperature heat treatment process called firing.
Types of reinforcement.
 1.Particle Composites
• Particles usually reinforce a composite equally in all directions
(called isotropic). Plastics, cermets and metals are examples of
particles.
• Particles used to strengthen a matrix do not do so in the same
way as fibers. For one thing, particles are not directional like
fibers. Spread at random through out a matrix, particles tend to
reinforce in all directions equally.
 Cermets
(1) Oxide–Based cermets
(e.g. Combination of Al2O3 with Cr)
(2) Carbide–Based Cermets
(e.g. Tungsten–carbide, titanium–carbide)
 Metal–plastic particle composites
(e.g. Aluminum, iron & steel, copper
particles)
 Metal–in–metal Particle Composites
and Dispersion Hardened Alloys
(e.g. Ceramic–oxide particles)
 2.Flake composites
Flakes, because of their shape, usually reinforce in 2-D. Two
common flake materials are glass and mica. (Also aluminum is used
as metal flakes)
A flake composite consists of thin, flat flakes held together by a
binder or placed in a matrix. Almost all flake composite matrixes are
plastic resins. The most important flake materials are:
1.Aluminum
2. Mica
3. Glass
Basically, flakes will provide:
• Uniform mechanical properties in the plane of the
flakes
• Higher strength
• Higher flexural modulus
• Higher dielectric strength and heat resistance
• Better resistance to penetration by liquids and vapor
• Lower cost
 3.Filled Composites
There are two types of filled composites. In one, filler materials are
added to a normal composite result in strengthening the composite and
reducing weight. The second type of filled composite consists of a
skeletal 3-D matrix holding a second material. The most widely used
composites of this kind are sandwich structures and honeycombs.
 4.Fiber reinforced composites
These are the most popular and widely used composites in practice
A fiber-reinforced composite (FRC) is a composite building
material that consists of three components: (i) the fibers as the
discontinuous or dispersed phase, (ii) the matrix as the continuous phase,
and (iii) the fine interphase region, also known as the interface, This is a
type of advanced composite group, which makes use of rice husk, rice
hull, and plastic as ingredients. This technology involves a method of
refining, blending, and compounding natural fibers from cellulosic waste
streams to form a high-strength fiber composite material in a polymer
matrix. The designated waste or base raw materials used in this instance
are those of waste thermoplastics and various categories of cellulosic
waste including rice husk and saw dust.
The typical composite consists of a matrix holding reinforcing
materials. The reinforcing materials, the most important is the fibers,
supply the basic strength of the composite. However, reinforcing
materials can contribute much more than strength. They can conduct heat
or resist chemical corrosion. They can resist or conduct electricity. They
may be chosen for their stiffness (modulus of elasticity) or for many
other properties.
 Fibre reinforced composites
The fibers are divided into two main groups:
 Glass fibers: There are many different
kinds of glass, ranging from ordinary
bottle glass to high purity quartz glass. All
of these glasses can be made into fibers.
Each offers its own set of properties.
 Advanced fibers: These materials offer
high strength and high stiffness at low
weight. Boron, silicon, carbide and
graphite fibers are in this category. So are
the aramids, a group of plastic fibers of
the polyamide (nylon) family.
 Production of carbon fibers.
Composites materials made by reinforcing carbon fibers in epoxy
resin matrix are well known for their combination of properties such
as light weight, very high strength and high stiffness.
Such composites are especially attractive for aerospace applications
but relatively high cost.
Carbon fibbers for those composites are mainly produced from a
source called POLYACRYLONITRILE (PAN) Thorough 3 stages.

a) Stabilization b) carbonization c) Graphitization

 Laminated composites
composite laminates are assemblies of layers of fibrous composite
materials which can be joined to provide
required engineering properties, including in-plane stiffness, bending
stiffness, strength, and coefficient of thermal expansion.

Layers of different materials may be used, resulting in a hybrid laminate.

The individual layers generally are orthotropic (that is, with principal
properties in orthogonal directions) or transversely isotropic (with isotropic
properties in the transverse plane) with the laminate then
exhibiting anisotropic (with variable direction of principal properties),
orthotropic, or quasi-isotropic properties.

Depending upon the stacking sequence of the individual layers, the

laminate may exhibit coupling between inplane and out-of-plane response.
An example of bending-stretching coupling is the presence of curvature
developing as a result of in-plane loading.
 Laminar Composite Structure
Two or more layers bonded together in an integral piece
• Example: plywood in which layers are the same wood, but grains
are oriented differently to increase overall strength of the
laminated piece
 Sandwich composites
These are the class of composites materials used for light weight and high stiffness.

A sandwich-structured composite is a special class of composite materials that is

fabricated by attaching two thin but stiff skins to a lightweight but thick core. The core
material is normally low strength material, but its higher thickness provides the
sandwich composite with high bending stiffness with overall low density.

Sandwich structures can be widely used in sandwich panels, this kinds of panels can
be in different types such as FRP sandwich panel,aluminium composite panel etc.
 Sandwich Structure – Foam Core
• Consists of a relatively thick core of
low density foam bonded on both faces
to thin sheets of a different material

Sandwich Structure – Honeycomb

Core
An alternative to foam core Either
foam or honeycomb achieves high
strength-to-weight and
stiffness-to-weight
 The Role of interface
• There is always an interface between constituent phases in a composite
material
• For the composite to operate effectively, the phases must bond where they
join at the interface
• In some cases, a third ingredient must be added to achieve bonding of
primary and secondary phases
• Called an interphase, this third ingredient can be thought of as an
adhesive
• Other properties such as creep resistance, fatigue resistance,
environmental degradation etc.,

Interfaces between phases in a

composite material: (a) direct bonding
between primary and secondary phases
Fundamentals of production of metal matrix composites.
(MMC’S)

Foundry technique
Powder metallutgy technique
 Electroforming
Vapour depossition
Liquid metal infiltration
Diffusion bonding etc.,

MMC’S are formed with all the different dispersoids

namely fibres, whiskers and particulates.
Foundry technique: MMC’s can be produced by foundry technies
in a simple and cost effective manner
Examples are sand casting, die casting, centrifugal casting and
squeeze casting etc.,
Fundamentals of production of fiber reinforcement
plastics (FRP’S)
Molding operations are used in making a large number of
common composite products. There are two types of
processes:

A. Open–mold
(1) Hand lay–up
(2) Spray–up
(3) Vacuum–bag molding
(4) Pressure–bag molding
(5) Thermal expansion molding
(6) Autoclave molding
(7) Centrifugal casting
(8) Continuous pultrusion and pulforming.
 Open–mold methods
1. Hand lay–up or wet lay up or bucket and brush method.
Hand lay–up, or contact molding, is the oldest and simplest way of
making fiberglass–resin composites. Applications are standard wind
turbine blades, boats, etc.)
 2.Bag molding composites
a). Vacuum bag molding b). Pressure bag molding c). Autoclave molding
. Vacuum-Bag Molding
The vacuum–bag process was developed for making a
variety of components, including relatively large parts
with complex shapes. Applications are large cruising
boats, racecar components, etc.
 . Pressure-Bag Molding
Pressure–bag process is virtually a mirror image of
vacuum–bag molding. Applications are sonar domes,
antenna housings, aircraft fairings, etc.
 Autoclave Molding
Autoclave molding is similar to both vacuum–bag and
pressure–bag molding. Applications are lighter, faster and
more agile fighter aircraft, motor sport vehicles.
 3. Filament winding process.
Highly automated low manufacturing costs if high throug hput
e.g., Glass fiber pipe, sailboard masts
 4.Spray-up
In Spray–up process, chopped fibers and resins are sprayed
simultaneously into or onto the mold. Applications are lightly
loaded structural panels, e.g. caravan bodies, truck fairings,
bathtubes, small boats, etc.
 2.Closed mold processes
(1) Matched–die molding: As the name
suggests, a matched–die mold consists of
closely matched male and female dies
(shown in figure). Applications are
spacecraft parts, toys, etc.
(2) Injection molding: The injection process
begins with a thermosetting (or sometimes
thermoplastic) material outside the mold.
The plastic may contain reinforcements or
not. It is first softened by heating and/or
mechanical working with an extrusion–
type screw. It is then forced, under high
pressure from a ram or screw, into the cool
mold. Applications are auto parts, vanes,
engine cowling defrosters and aircraft
radomes.
1.Sheet Molding Compound (SMC)
– Chopped glass fiber added to polyester resin mixture
Pultrusion process
Pultrusion
 Why Composites are Important
• Composites can be very strong and stiff, yet very
light in weight, so ratios of strength-to-weight
and stiffness-to-weight are several times greater
than steel or aluminum
• Fatigue properties are generally better than for
common engineering metals
• Toughness is often greater too
• Composites can be designed that do not corrode
like steel
• Possible to achieve combinations of properties
not attainable with metals, ceramics, or polymers
alone
 Advantages of Composites
1.Higher Specific Strength (strength-to-weight ratio)
Composites have a higher specific strength than many other materials. A
distinct advantage of composites over other materials is the ability to use
many combinations of resins and reinforcements, and therefore custom tailor
the mechanical and physical properties of a structure.
2.Design flexibility
Composites have an advantage over other materials because they can be molded
into complex shapes at relatively low cost. This gives designers the freedom to create
any shape or configuration. Boats are a good example of the success of composites.

3.Corrosion Resistance
Composites products provide long-term resistance to severe chemical and
temperature environments. Composites are the material of choice for outdoor
exposure, chemical handling applications, and severe environment service.
4.Low Relative Investment
One reason the composites industry has been successful is because of the
low relative investment in setting-up a composites manufacturing facility. This
has resulted in many creative and innovative companies in the field.
 Disadvantages of Composites
1.Composites are heterogeneous
properties in composites vary from point to point in the material. Most
engineering structural materials are homogeneous.

2.Composites are highly anisotropic

.
3.Composites materials are difficult to inspect with conventional
ultrasonic, eddy current and visual NDI methods such as radiography.
4.Composites materials are more expensive than conventional
materials, mainly those in aerospace and high performance industries.
5.The most difficult part of composite development is testing and
inspection.
6.Maching of composite s difficult which may induce damage.
7.Composite fabrication requires extra care as chemicals are involved.
8.Cost of composite is higher when volume of production is less.
9.Composite fabrication requires high investment on machineries and
equipment.
Applications of composite materials
 Composite materials in the Boeing 757
(courtesy of Boeing Commercial Airplane Group)
 Transportations
 Civil construction
 Biomedical
 Sports
 Aerospace industry