COMPOSITE

MATERIALS

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WHAT IS COMPOSITES?

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Composite materials are engineered materials
made from two or more constituent materials
with significantly different physical or
chemical properties which remain separate and
distinct on a macroscopic level within the
finished structure.
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180px-Kohlenstofffasermatte

A cloth of woven carbon fiber filaments, a common element in

composite materials

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 PROPERTIES OF

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COMPOSITES

Specific strength[1]
Expense[1]
Application[1]
Processability[1]
Orthotropic [2]
Inhomogeneous[3]
Do not dissolve or merge completely into another[4] 4
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APPLICATION OF

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COMPOSITES
aircraft industry
space industry
auto and transportation industry
utility industry
chemical industry
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some examples of composites

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civil infrastructure such as bridges, roads, earthquake
retrofitting of buildings etc.
various aircraft, helicopters and rockets
engine parts
marine vessels
sports
printed circuit board
large trucks
shipping containers
tank
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ships
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COMPONENTS OF
COMPOSITES

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Matrix phase: bulk materials such as: Metals,
Ceramics, Polymers
 Reinforcement: fibers and particulates such as:
Glass, Carbon,Kevlar, Silicon Carbide,
Boron,Ceramic, MetallicAggregate
Interface: area of mechanical
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Composite properties determined by the
matrix:

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Transverse mechanical properties
Interlaminar shear strength
Compressive strength
Plasticisation of the matrix
Service temperature
Fire and corrosion resistance
Tool design and fabrication process 9 9
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Composite properties influenced by fibres:
Rigidity (Modulus of elasticity)

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Tensile Longitudinal Strength
Initiation of fracture of fibres

Properties controlled by Interface / bonding:

Fracture energy/Fracture toughness
Interlaminar fracture energy

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 TYPES OF COMPOSITES

1 . PA RT I C U L AT E – R E I N F O R C E D
COMPOSITE

2. FIBER – REINFORCED COMPOSITE

3. STRUCTURAL COMPOSITE

3.A. LAMINAR COMPOSITE

3 . B . P L AT E C O M P O S I T E
1. Particulate – Reinforced
Composite

Dr. Uğur SOY, Sakarya Üniversitesi, Kompozit Malzemeler, Ekim 2009

-A composite that consists of tiny particles of one material embedded

in another material.

- Particles are most often used to extend the strength or other

properties of inexpensive materials by the addition of other materials.
 http://info.lu.farmingdale.edu/depts/met/met205/particlerc.JPG

-Particles may have any shape or size, but are generally spherical, ellipsoidal,
polyhedral, or irregular in shape.

-They may be added to a liquid matrix that later solidifies; grown in place by a
reaction such as agehardening.
 2. Fiber – Reinforced
Composite (FRC)

Dr. Uğur SOY, Sakarya Üniversitesi, Kompozit Malzemeler, Ekim 2009

- A FRC consists of three components: (i) fibers as the discontinuous or dispersed

phase, (ii) the matrix as the continuous phase, and (iii) the fine interphase region.

-Fibers increase the modulus of the matrix material.

-The strong covalent bonds along the fiber's length gives them a very high
modulus in this direction.
 http://info.lu.farmingdale.edu/depts/met/met205/composites.html

- Consideration of orientation and fiber length for a particular composites

depends on the level and nature of the applied stress.

- Fibers have a very high modulus along their axis, but have a low modulus
perpendicular to their axis.
3. Structural Composite
3.a. Laminar Composite

Dr. Uğur SOY, Sakarya Üniversitesi, Kompozit Malzemeler, Ekim 2009

- Laminar composites are composed of two-dimensional

sheets or panels that have a preferred high strength direction.
3. Structural Composite
3.b. Plate Composite

- Composites that composed of plate shape reinforcement agents in the

matrix phase.
 ADVANTAGES OF COMPOSITES

Weight saving

Very high specific strength

Great freedom of shape

Less parts, longer life

Material can be tailored

Thermal isolation habits

 Chemical resistance against acids etc.

Electrical habits

Impact habbits

EXCELLENT
Weather / water resistance

Excellent fatigue endurance

RAM features (Radar Absorbing Materials)

Resistance to corrosion and aggressive media

man-hours needed for maintenance

of structures (painting, repair,
replacement of components)

Reduction of environmental impact

storage costs of semi-finished products

 DISADVANTAGES OF COMPOSITES

High cost (compared to metals)

Expensive raw materials

Manufacturing time

Difficult to repair

Insufficient design data

 It is the fastest growing "materials" market segment

Automotive
Composites are used in a variety of automotive components,
from original equipment like driveshafts and truck beds, to
after-market equipment like camper shells.

Aerospace
strong enough to take harsh
loading conditions such as
aerospace components (tails,
wings, fuselages, propellers)
Full Composite Aircraft FAJR-3
Various composite materials are used in structures such as the Boeing 777
because of their strength, and weight savings. Composites also offer
resistance to fatigue, corrosion and impact damage.

http://www.aviation-history.com/theory/composite.htm
 World’s 1st Thermoplastic composite boat hull
(courtesy of VT Halmatic Ltd)
boat and scull hulls

bicycle frames and racing car bodies

http://www.eplcompositesolutions.co.uk/compo
Thermoplastic composite wind turbine site/VacuumMouldingCompositeStructures.asp

fishing rods, storage tanks,

and baseball bats
 engine parts

The need for weight reduction and increased

engine rpm in race cars like this one has
motivated serious research into engine valves of
carbon fiber-reinforced polymer composites.

chemical industry
Valves molded using the CSU team’s carbon braid-
reinforced, high-temperature polyimide resin.
Soure: D. Radford, Colorado State University marine vessels
 POLYMER
COMPOSITEs
1.Polymer Compositesand General Concepts
2.Structure and Components of Polymer Composites
3.Classification of Polymer Composites
4.Shaping of the Polymer Composites
5.Usage Areas of Composites In Daily Life
• The polymer composites have another name called Polymer Matrix
Composites (PMC).

• A polymer matrix composite (PMC) is a composite material composed of a

variety of short or continuous fibers bound together by an organic polymer
matrix. PMCs are designed to transfer loads between fibers of a matrix.

• Another Definition :
A composite material is a material made from two or more constituent
materials with significantly different physical or chemical properties that, when
combined, produce a material with characteristics different from the individual
components.
➢ Lightweight,

➢ High stiffness,

➢ High strength along the direction of

their reinforcements,

➢ Good abrasion resistance,

➢ Good corrosion resistance.

A polymer composite is a multi-phase material in which reinforcing
fillers are integrated with a polymer matrix, resulting in synergistic
mechanical properties that cannot be achieved from either component
alone.
Modern composites are usually made of two components :
• Fiber
• Matrix

FIBER
The fiber is most often glass, but sometimes Kevlar, carbon fiber, or polyethylene.
MATRIX
The matrix is usually a thermoset like an epoxy resin, polydicyclopentadiene, or a polyimide.
The properties of the matrix determines the resistance of the PMC to processes that includes
impact damage, water absorption, chemical attack, and high-temperature creep.

➢ The fiber is embedded in the matrix in order to make the matrix stronger. Fiber-reinforced
composites have two things going for them. They are strong and light. They're often
stronger than steel, but weigh much less. This means that composites can be used to make
automobiles lighter, and thus much more fuel efficient. This means they pollute less, too.
1. Environmental degradation.

2. Moisture absorption from environment causes swelling in the polymer as well as a

decrease of Tg.

3.The moisture absorption increases at moderately high temperatures. These

hydrothermal effects can lead to internal stresses in the presence of fibres in polymer
composites.

4. A thermal mismatch between polymer and fibre may cause cracking or debonding at
the interface.
The performance of polymer composites is generally determined by:

1. The properties of the fiber,

2. The properties of the polymer matrix,
3.The ratio of the fiber to the polymer matrix in the composite (fiber volume fraction),
and
4. The geometry and orientation of the fiber in the composite.

➢ The performance is usually referred to as the mechanical properties of the polymer

composites. It is considered to be the most important of the physical and chemical
properties of the polymer composites.
Mechanical properties of composites are strongly
influenced by the:

• size

• type

• concentration

• dispersion of reinforcing agent (filler)

• interfacial tension between the matrix and filler

There are 2 types of classifications about polymer composites

1. Classification according to their source

• Fibre-Composites
• Natural-Fibre Composites
• Bio-Composites

1. Classification according to polymer matrix

• Thermoplastic
• Thermoset
• Rubber
Classification According To Their Source:

A) Fibre-Composites (fiber-reinforced composite):

• FRC is high-performance fiber composite achieved and made possible by cross-linking cellulosic fiber
molecules with resins in the FRC material matrix through a proprietary molecular re-engineering process,
yielding a product of exceptional structural properties.
• Through this feat of molecular re-engineering selected physical and structural properties of wood are
successfully cloned and vested in the FRC product, in addition to other critical attributes to yield
performance properties superior to contemporary wood.
• This material, unlike other composites, can be recycled up to 20 times, allowing scrap FRC to be reused
again and again.

B) Natural-Fibre Composites (NFC):

• Natural fibre composites (NFCs) are composite materials, in which at least the reinforcing fibres are
derived from renewable and carbon dioxide neutral resources such as wood or plants. Natural fibre
composites could be 100% biodegradable. Biological and environmental durability is often cited as a key
advantage of natural fibre composites over traditional materials.
C) Bio-Composites:
A biocomposite is a composite material formed by a matrix (resin) and a reinforcement of natural
fibers. These kind of materials often mimic the structure of the living materials involved in the process
keeping the strengthening properties of the matrix that was used, but always providing
biocompatibility. The matrix phase is formed by polymers derived from renewable and nonrenewable
resources. Biocomposites are divided into non-wood fibers and wood fibers, all of which present
cellulose and lignin. In addition, biofibers are the principal components of biocomposites, which are
derived from biological origins, for example fibers from crops (cotton, flax or hemp), recycled wood,
waste paper, crop processing byproducts or regenerated cellulose fiber (viscose/rayon).
Classification According To Polymer Matrix:

A) Thermoplastic-Composites (TMC):

• Thermoplastic composites (TMCs) evolved from structural polymer composites. These materials do
not experience chemical instability because they utilize a thermoplastic matrix. When heated, TMCs
soften and can be remolded without degradation. When they cool, they solidify into the finished
shape. This heating-cooling cycle can be repeated multiple times, giving the product an almost
indefinite shelf life.

• Thermoplastic composites could also be shaped using techniques derived from wood and
metalworking. They have increased recycling and damage tolerances due to the tough nature of the
matrix material.

• Thermoplastic composites could be categorized into either Glass Mat Thermoplastics (GMT) or
Advanced Thermoplastic Composites (ATC).
 B) Thermoste-Composites:

• Thermoset composites, which are commonly based on glass,

carbon or aramid fibers, are usually incorporated with resins such
as polyesters, vinyl esters, epoxies, bismaleimides, cyanate esters,
polyimides or phenolics.

• The recycling options for thermoset composites are limited

C) Rubber-Composites:
• Reinforced rubber products combine a rubber matrix and
a reinforcing material, so high strength to flexibility
ratios can be achieved. The reinforcing material, usually
a kind of fibre, provides the strength and stiffness. The
rubber matrix, with low strength and stiffness, provides
air-fluid tightness and supports the reinforcing materials
to maintain their relative positions. These positions are of
great importance because they influence the resulting
mechanical properties.
 Basic necessities for
any process...
Reinforcement
- to define initial architecture of reinforcement.
Shaping

- compressing reinforcement, or maybe prepreg, to final shape

Part Shape of the part.
Definition - usually done within a mould, or die.

Matrix - to fully immerse the reinforcing fibres in the polymer matrix.

Infusion - should expel all air, or voids, from part.

Matrix - to provide for the necessary cure of a thermoset, or

Solidification solidification of a thermoplastic.
Composite fabrication processes

A. Spray lay-up:
Chopped fibre (glass) and resin + catalyst ( i.e. polyester) mixed in a hand-held gun
and sprayed directly into the mould or on to the structure. Gives a random 2-D fibre
array.

B. Wet lay-up, Hand lay-up:

Resins impregnated by hand (using rollers or brushes) into fibres (generally in the
form of woven cloth). Only suitable for low-viscosity resins (may be warmed). Left to
cure at room temperature. Roller used to spread resin and remove bubbles Gelcoat
(resin only) on mould surface used to obtain good surface finish
C. Vacuum bagging:
• An extension of (b), but quality improved by applying hydrostatic (air)
pressure through a flexible membrane before and during curing. Mould
may be heated if the process is used to make finished goods; less easily
done in the field for on-site repairs.
• The material may be supplied in the form of pre-preg (cloth plus uncured
matrix resin in sheet or tape form)
D. Filament Winding:
Generally used for hollow (circular or oval sectioned)
components, though large curved sheets can also be made
by carving these up after winding. Fibre tows are passed
through a resin bath before being wound onto a mandrel in a
variety of orientations.

E. Pultrusion:
Fibres pulled through a resin bath and then through a die.
If the composite is being produced in final form, the die is
heated to cure the resin. Pultruded product may be small
bundles or tapes of multiple fibres for subsequent
processing, sheets (laminae, which are used for lay-up
processes) or any extruded sections (e.g. rods, I-beams).
F. Resin Transfer Moulding (RTM):
Fibre cloth stacked up as a preform in a closed cavity mould, resin injected (if
under vacuum, process known as Vacuum Assisted RTM), component cured in
mould.
Construction of:
• Buildings
• Bridges
• Housing
• Lampposts
• Smokestacks
• Highway culverts