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Composite Materials

The document discusses composite materials, which are composed of two or more physically distinct phases. Composite materials can be designed to be strong and light. They have advantages like high strength-to-weight ratios, better fatigue properties than metals, and resistance to corrosion. Disadvantages include anisotropic properties, susceptibility to chemical attack, high costs, and slow manufacturing methods. The document then describes different types of composite materials including metal matrix composites, ceramic matrix composites, and polymer matrix composites. It provides details on the components, properties, and applications of these material systems.

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76 views27 pages

Composite Materials

The document discusses composite materials, which are composed of two or more physically distinct phases. Composite materials can be designed to be strong and light. They have advantages like high strength-to-weight ratios, better fatigue properties than metals, and resistance to corrosion. Disadvantages include anisotropic properties, susceptibility to chemical attack, high costs, and slow manufacturing methods. The document then describes different types of composite materials including metal matrix composites, ceramic matrix composites, and polymer matrix composites. It provides details on the components, properties, and applications of these material systems.

Uploaded by

Billy Jhun
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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9 COMPOSITE

MATERIALS
PREPARED BY:
GROUP 5
Arpon, Maryann
Cator, Mabelle
Dagami, Aramae
Morecho, Alexander
Ranin, Junard
Salve, Luke
COMPOSITE MATERIALS
-is a material system composed of two or more physically distinct phases whose combination produces
aggregate properties that are different from those of its constituents
-the most interesting of the engineering materials because their structure is more complex than the other
types
Advantages
1. Composites can be designed that are very strong and stiff, yet very light in weight, giving them
strength-to-weight and stiffness-to-weight ratios several times greater than steel or aluminum.
2. Fatigue properties are generally better than for the common engineering metals.
3. Composites can be designed that do not corrode like steel.
4. With composite materials, it is possible to achieve combinations of properties not attainable
with materials, ceramics, or polymers alone.
5. Better appearance and control of surface smoothness are possible with certain composite
materials.
Disadvantages
1. Properties of many important composites are an isotropic, which means the properties differ
depending on the direction in which they are measured.
2. Many of the polymer-based composites are subject to attack by chemicals or solvents, just as
the polymers themselves are susceptible to attack.
3. Composite materials are generally expensive, although prices may drop as volume increases.
4. Certain of the manufacturing methods for shaping composite materials are slow and costly
9.1 Technology and Classification of
Composite Materials
PHASE- indicates a homogeneous material, such as metal or ceramic in which all of the grains have the same
crystal structure, or a polymer with no fillers.

2 TYPES OF COMPOSITE MATERIALS


1. Traditional Composites
-occurs in nature or have been produced by civilizations for many years
2. Synthetic Composites
-modern material systems normally associated with the manufacturing industries in which the
components are first produced separately and then combined in a controlled way to achieve
the desired structure, properties, and part geometry
9.1.1 Components in a Composite Material

2 PHASES OF COMPOSITE MATERIALS


1. Primary Phase
-it forms the matrix within which the secondary phase is embedded
-can be any of three basic material types: polymers, metals, or ceramics
2. Secondary Phase
-sometimes referred to as a reinforcing agent because it usually serves to strengthen the composite
-it may be an element such as carbon or boron
9.1.1 Components in a Composite Material

TABLE 9.1 Possible combinations of two-component composite materials

Secondary Phase Primary Phase (matrix)


(reinforcement)
Metal Ceramic Polymer
Metal Powder with metal parts infiltrated NA Plastic molding compounds Steel-
with a second metal belted radial tires
Ceramic Cerments SiC whisker- Plastic molding compounds
Fiber-reinforced metals reinforced Fiberglass-reinforced plastic
NA
Polymer Powder metal parts impregnated with Plastic molding compounds
polymer NA Kevlar-reinforced epoxy
Elements (C, B) Fiber-reinforced materials Rubber with carbon black
B or C fiber-reinforced plastic
9.1.1 Components in a Composite Material
3 CLASSIFICATION SYSTEM FOR COMPOSITE MATERIALS
1. 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.
2. Ceramic Matrix Composites (CMCs)
-Aluminum oxide and silicon carbide are materials that can be imbedded with fibers for
improved properties, especially in high temperature
3. Polymer Matrix Composites (PMCs)
-Thermosetting resins are the most widely used polymers in PMCs. Epoxy and polyester are
commonly mixed with fiber reinforcement, and phenolic is mixed with powders
9.1.2 The Reinforcing Phase

FIBERS- filaments of reinforcing material, generally circular in cross-section, although alternative


shapes are sometimes used (e.g., tubular, rectangular, hexagonal).
9.1.2 The Reinforcing Phase

2 CLASSIFICATION OF FIBERS
1. Continuous Fibers
-they offer a continuous path by which a load can be carried by the composite part
2. Discontinuous Fibers
-(chopped sections of continuous fibers) are short lengths (L/D 100). An important type of
discontinuous fiber are whiskers—hair-like single crystals with diameters down to about
0.001 mm (0.00004 in) and very high strength.
9.1.2 The Reinforcing Phase

3 CASES OF FIBER ORIENTATION


1. One-dimensional Reinforcement
-maximum strength and stiffness are obtained in the direction of the fiber 2. Planar
Reinforcement
-in some cases in the form of a two-dimensional woven fabric
3. Random or Three-dimensional
-composite material tends to possess isotropic properties
9.1.2 The Reinforcing Phase

6 TYPES OF FIBER MATERIALS


1. Glass
2. Carbon
3. Boron
4. Kevlar49
5. Ceramics
6. Metal
9.1.2 The Reinforcing Phase

PARTICULATE- a second common shape of the imbedded phase ranging in size from microscopic to
macroscopic.
FLAKES- a two-dimensional particles—small flat platelets

INFILTRATED PHASE
The fourth form of imbedded phase occurs when the matrix has the form of a porous skeleton
(like a sponge), and the second phase is simply a filler.
9.1.2 The Reinforcing Phase

THE INTERPHASE - this third ingredient can be thought of as an adhesive. An important example is
the coating of glass fibers to achieve adhesion with thermosetting resin in fiberglass-reinforced
plastics.
9.1.2 The Reinforcing Phase
9.1.3 Properties of Composite Materials

3 FACTORS OF COMPOSITE MATERIALS


1. the materials used as component phases in the composite
2. the geometric shapes of the constituents and resulting structure of the composite system
3. the manner in which the phases interact with one another
9.1.3 Properties of Composite Materials

RULE OF MIXTURES- involves calculating a weighted average of the constituent material properties
9.1.4 Other Composite Structures

LAMINAR COMPOSITE STRUCTURE consists of two or more layers bonded together to form an
integral piece.
9.1.4 Other Composite Structures
9.2 Metal Matrix Composites

Metal matrix composites (MMCs) consist of a metal matrix reinforced by a second phase. Common
reinforcing phases include (1) particles of ceramic and (2) fibers of various materials, including
other metals, ceramics, carbon, and boron. MMCs of the first type are commonly called cermets.
9.2.1 Cermets

CERMETS- is a composite material in which a ceramic is contained in a metallic matrix. The ceramic
often dominates the mixture, sometimes ranging up to 96% by volume.

Cemented Carbides – composed of one or more carbide compounds bonded in a metallic matrix
Tungsten Carbide- cutting tools are the most common application of cemented carbides
Titanium Carbide- are used principally for high temperature applications
Chromium Carbide- are more brittle but have excellent chemical stability and corrosion resistance
9.2.2 Fiber-Reinforced Metal Matrix
Composites
These MMCs are of interest because they 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. Typical metals used as the low-density matrix
are aluminum, magnesium, and titanium. Some of the important fiber materials used in the
composite include Al2O3, boron, carbon, and SiC.
9.3 Ceramic Matrix Composites

Ceramics have certain attractive properties: high stiffness, hardness, hot hardness, and
compressive strength; and relatively low density. Ceramics also have several faults: low toughness
and bulk tensile strength, and susceptibility to thermal cracking.
9.4 Polymer Matrix Composites

POLYMER MATRIX COMPOSITE (PMC) consists of a polymer primary phase in which a secondary
phase is imbedded in the form of fibers, particles, or flakes. Commercially, PMCs are the most
important of the three classes of synthetic composites. They include most plastic molding
compounds, rubber reinforced with carbon black, and fiber-reinforced polymers (FRPs).
9.4.1 Fiber-Reinforced Polymers

FIBER-REINFORCED POLYMER - a composite material consisting of a polymer matrix imbedded with


high-strength fibers.

ADVANCED COMPOSITES - sometimes used in connection with FRPs developed since the late 1960s
that use boron, carbon, or Kevlar, as the reinforcing fibers [13]. Epoxy is the common matrix
polymer.

HYBRID COMPOSITE- when two or more fiber materials are combined in the FRP composite
9.4.1 Fiber-Reinforced Polymers

PROPERTIES
1. high strength-to-weight ratio
2. high modulus-to-weight ratio
3. low specific gravity
4. good fatigue strength
5. good corrosion resistance
6. low thermal expansion
7. significant anisotropy in properties
9.4.2 Other Polymer Matrix Composites

FILLERS- ingredients of the secondary phase

2 CATEGORIES OF FILLERS
1. Reinforcements
-serve to strengthen or otherwise improve mechanical properties of the polymer.
2. Extenders
-simply increase the bulk and reduce the cost-per-unit weight of the polymer, but have little or no effect
on mechanical properties.

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